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May 2012

Technological Developments in the Design of Electric Motors for Hazardous Areas

Alex Settimi Sohler, WEG Australia Pty Ltd


Eribert Augusto Neves, WEG Motors Engineering Department
Samir Grifante, WEG Motors Engineering Department

ABSTRACT All these tasks, marketers, engineering disciplines, minds


Developing an electric motor range is a vexed and and personalities need to collaborate throughout 18 to 24
challenging task. IEC60034 and IEC60072 series months to develop a full range of electric motors.
standards establish clear requirements for torque,
temperature, speed, vibration, noise level, dimensions The starting point is a market study, from which a clear
among others. Hazardous area standards, such as value proposition and target markets will be established.
IEC60079 series, add a greater level of complexity with Once the strategic marketing brief is handed over to the
various specific and mandatory design criteria. In engineering team, the design task commences. The basis of
addition, with the push for high efficiency motors, any design are the standards pertinent to the target
spearheaded by IEC60034-30 and AS1359.5, the challenge markets, for instance, IEC or NEMA, Australia or Europe,
for manufacturers is to reconcile all the stipulations mining or petrochemical. By and large from an Australian
without compromising safety. This paper reviews the main perspective the relevant standards will be:
constraints, technological breakthroughs and design
developments for a state-of-the-art range of low and high  IEC/AS 60034 series
voltage Ex-d motors.  IEC 60072 series
 IEC/AS 60079 series
INTRODUCTION  AS 1359.5
The design of an electric motor range is a complex, time
consuming endeavor requiring the collaboration of a This paper provides an insight into the design and
multidisciplinary team of engineers and specialists. On a technological developments of a state-of-the-art Ex-d
macro level it will necessarily involve the following electric motor range. It correlates the standards to
disciplines whose main areas of concern are listed below: practical design and application requirements, and expands
on topics yet unaddressed by current standards.
 Marketers: define the market and market segments the
products will be sold at, benchmark current offerings
and conduct gap analyses, determine the value
proposition of new products, define range and
features, determine certifications needed, produce
marketing material, prices and train the sales force.

 Electrical Engineering: winding design,


electromagnetic flux and torque range, efficiency,
power factor, electromagnetic noise, insulation grade,
voltage and frequency, surge withstandability, VSD
compatibility and surge level, temperature rise

 Mechanical Engineering: frame design and robustness


level, endshield, flanges, bearing cap, bearing housing
tolerances and L10 life, fans, fan cowls, accessories
such as brakes and encoders, mounting configuration,
axial and radial thrust design range, shaft and rotor
suitable for the torque range in electrical design.
Figure 1: Ex-d motor cut-away picture (courtesy of WEG)
 Industrial Engineering: responsible for ensuring
choice of design, electrical and mechanical, can be Amongst hazardous area motor types (Ex-nA, Ex-t, Ex-e
physically implemented at the factory, ordering and
Ex-d and Ex-p) Ex-d flameproof was chosen for it
supervising the make of tools needed to manufacture
parts, factory lay-out and product flow design. represents the highest level of safety and most complex
design. A flameproof enclosure is defined as per IEC
 Quality Control Engineering: quality manuals, 60079-1 (2003: p. 15) as an “ enclosure in which the parts
manufacturing instructions, check points, quality which can ignite an explosive atmosphere are placed and
control tests, procedures. which can withstand the pressure developed during an
internal explosion of an explosive mixture, and which
 Certifications Engineering: liaise with relevant prevents the transmission of the explosion to the explosive
certifying bodies to certify range and quality control atmosphere surrounding the enclosure”.
process.

Technological Developments in the Design of Electric Motors for Hazardous Areas Page 1
May 2012

especially prominent in larger motors (45kW and above)


ELECTRICAL DESIGN due to their already low electrical resistances as shown in
The electrical design for Ex-d type motors is largely Figures 3 and 4.
similar to safe area motors. In the interest of keeping this
paper within a manageable length, attention is focused on 4 Poles
3.5
the special challenges arising out of the new efficiency
3.0
standards and the use of VSD, in particular the impact 2.5

Torque-Locked Rotor
these have on the motor electrical design for hazardous 2.0

areas. 1.5 MEPS


High Efficiency
1.0

Efficiency & Torque 0.5

The requirements of AS 1359.5-2004 and IEC 60034-30, 0.0


5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 132
which mandate minimum efficiency levels for standard kW

and high efficiency electric motors cannot go unnoticed.


The increase in motor efficiency is generally achieved by
Figure 3: Locked rotor torque of MEPS2 and MEPS2 High
using larger copper gauge wires and low loss lamination Efficiency range for an Australian supplier.
steel. This is the easier route for manufacturers, which
preserves the geometry of their laminations and therefore 2 Poles
the usability of existing stamping tools. However, such a 4.0

design philosophy has dire consequences to motor 3.5

breakdown and especially locked rotor torques. In fact the 3.0

Torque-Breakdown
2.5
introduction and evolution of these standards have resulted
2.0
in flatter torque speed curves as shown in Figure 2. MEPS
1.5
High Efficiency
1.0

0.5

0.0
5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 132
kW

Figure 2: Torque speed curves of AS1359.4 motors from Figure 4: Breakdown torque of MEPS2 and MEPS2 High
Efficiency range for an Australian supplier.
first edition in 2001 (MEPS1) to second edition in 2004
(MEPS2 and MEPS 2 high efficiency) – T is torque and n
speed
Limitations of Low Torque Motors
An electric motor is defined as a machine which converts
electrical energy into mechanical energy. The latter is
This is explained by looking at the equations that provide in the form of torque at a certain speed. Its primary
determine the breakdown torque (Tbd) and locked rotor purpose is therefore to provide torque. A motor with low
torque (Tlr). locked rotor and breakdown torque has the following
disadvantages:
𝑉2 1
𝑇𝑏𝑑 = 3 2𝜋𝑛 (1)
2 (𝑟12 + 𝑋𝑐𝑐 2 +𝑟1)
• Decreased ability to start high inertia loads
𝑟2′ 𝑉2
• Decreased ability to cope with voltage sags
𝑇𝑙𝑟 = 3 2𝜋𝑛 𝑟2′ 2 • Decreased ability to cope with momentary overloads
(𝑟1+ ) +𝑋𝑐𝑐 2 (2)
𝑠
• Motor is more prone to stalling
High efficiency motors signify:
• Lower r1 and r2 values
• Higher X1 + X2 Efficiency & Inrush Current
A lower X/r ratio motor will have a higher locked rotor
current and, by extension, inrush current. The inrush
Note: Xcc >> r1 and r2
current can be calculated by analysing the motor’s voltage
and flux immediately after energising it. The voltage
By virtue of reducing the electrical resistances (r1 and r2) applied to the motor is:
to achieve higher efficiencies without regulating the
reactances (X1 and X2), e.g. keeping lamination design v(t) = Vm sin (ω + θ) (2)
unchanged, the higher efficiency is achieved with a
The maximum flux amplitude reached on the first half-
detrimental impact to motor locked rotor and breakdown cycle of the applied voltage depends on the phase of the
torque, which can decrease quite significantly. This is voltage at the time it is applied. If the initial voltage is

Technological Developments in the Design of Electric Motors for Hazardous Areas Page 2
May 2012

conductors there is a relative voltage, which gives rise to


v(t) = Vm sin (ω + 90) = Vm cosωt (4) an electric field. If the established electric field is high
enough (but below the breakdown voltage of the insulating
Supposing the initial flux in the core is zero, the maximum
material), the dielectric strength of the air is disrupted. For
flux during the first half-cycle will equal the flux at steady
state (5). this to happen though the voltage on the conductors must
exceed a threshold value, the so called “Corona Inception
= (5) Voltage”. That is, the local breakdown strength in air
(within the void). The CIV depends on the windings
design, insulation type, temperature, superficial
If the voltage displacement angle θ is 0 then the maximum characteristics and moisture (Pires, W. D. L, 2009). The
flux at the first half-cycle is given by equation 6 as
ensuing insulating damage is depicted in Figure 6.

= ∫ = = ( )

Equation 6 shows that the maximum flux can be twice as Partial discharge effect on the motor insulation system
Damaged insulation due
high as the steady state flux. By examining a motor’s to PD activity

magnetisation curve (see Figure 5) it can be seen that a Figure 6: PD damage on random wound insulation
small increase in flux results in an enormous increase in
the magnetization current. In fact, the inrush current can
reach a peak value of approximately 3 times the motor’s How Quickly A Motor Can Fail
locked rotor current (the latter is measured in r.m.s.). As it Premature failures of inverter–rated motors depend on the
lasts only a few cycles (some milliseconds), it is not adverse combination of properties of the inverter used, the
normally detected by conventional meters, but it is sensed length of cable, motor characteristics and PD level in the
by the instantaneous trip elements of circuit breakers, fuses air gaps of the motor insulation system.
or overcurrent relays, which may result in nuisance
tripping during motor starting.
These types of failures, when they occur, tend to be slow
onsetting over the course of a few years. In severe cases,
e.g. in high ambient temperatures such as Kilns (900 to
1100C), a winding failure may occur within a few months.
Short-term failures have also been observed in applications
with long-cable runs or with high dV/dt drive topologies.

Preserving Motor Life


From a systems engineer viewpoint a solution is needed to
render the inverter-driven motor a similar life span
obtained in a mains supply installation. There are
basically two approaches:

Figure 5: Electric motor magnetization curve a) Improve motor insulation endurance


b) Decrease the magnitude, frequency and speed of
voltage stresses
A higher locked rotor current also has a limiting effect on
the maximum number of starts a motor can perform per Motor insulation endurance is impacted by choice of:
hour, as it results in higher motor heating during start.  wire insulation (enamel type and thickness)
 phase and ground insulation
 impregnation system and material
Use with VSDs
VSDs or frequency converters generate voltage impulses  operating temperature
and fast transients (dV/dt) that stress the electric motor  cleanliness and dryness
insulation.
Special enamelled wire, commonly termed spike-resistant,
Partial Discharges (PD) is the most significant of all technological improvements.
The deterioration of the motor insulating system due to Resin-based impregnation methods which increase the
voltage overshoots occurs by means of PD, a complex percentage of retained solids improve the insulation’s
phenomenon resulting from Corona (Kaufhold, M.; overall partial discharge inception voltage (PDIV).
Börner, G.; Eberhardt, 1996). Between adjacent charged Keeping temperature low, the insulation clean and dry will

Technological Developments in the Design of Electric Motors for Hazardous Areas Page 3
May 2012

also maintain a high PDIV level. Although various containment ability of the frame, endshields and terminal
techniques exist, a common theme is that a special boxes. These are discussed in turn.
insulation system is required to produce a true inverter-rate
electric motor.

The Implications For Hazardous Areas


Standards such as AS /NZS 60079.20 quantify the ignition
energy of the gases comprising groups I and II. These
energy levels, herein reproduced in Table 1, can be quite
low.

Table 1: Ignition Energy for Groups I and II Gases


GROUP Ignition Minimum
Energy Igniting Current
I 525 µJ 85mA
IIA 320µJ 70mA
IIB 160µJ 40mA
IIC 40µJ 21mA Figure 7: Ex-d motor (W22EX range courtesy of WEG)

The phenomenon leading to a premature winding failure


in an inverter-driven electric motor is of a partial discharge Frame
(PD) nature. Whereas PD is an acceptable inherent The frame design must meet the following key criteria:
characteristic of medium and high voltage motors, above
4kV, there is generally not much consideration given to • It must be robust enough to contain an explosion and
PD activity in low voltage electric motors. The literature be used in various mounting configurations (IEC
has documented explosions with high voltage Ex-nA 60079-1 item 12)
motors attributed to partial discharges as the ignition • It must be ample enough to house the stator, rotor and
source (Jones, N., 1994: p. 20). The question whether the terminal box
PD energy in an inverter-driven motor may exceed the • It must provide enough surface area for efficient heat
ignition energy of the surrounding flammable gas, exchange (IEC 60079-0 item 5)
remains.

Based on Equipment Protection Levels (EPL) introduced


by AS/NZS 60079:26, would for instance an Ex-e inverter-
driven motor be classed as EPL Gb or Gc? In order to meet
Gb level it should not be “a source of ignition in normal
operation or when subject to faults that may be expected,
though not necessarily on a regular basis (2007: p. 12).”
Does the fact that partial discharges are expected to occur
in inverter-rated motors make it a source of ignition?

These are pointed questions yet to be answered by the


appropriate experimental research. Whereas the testing
regime to certify an Ex motor for use with inverter hones
in the temperature effects of harmonics and speed Figure 8: Ex-d motor frames 280 to 355 (W22EXEx range
variation, they do not make reference to discharge energy. courtesy of WEG)
It appears that certification alone may fall short of
addressing all safety concerns of using hazardous area
motors with inverters. Whilst this may not be a concern The frame design starts by determining the reference
for Ex-d type enclosures due to their explosion pressure of an internal explosion. This is the basis of all
containment requirement, it may pose a risk for explosion component designs, which are selected to provide a safety
avoidance type protections such as Ex-nA, Ex-e and Ex-t. factor over the forces created by an internal explosion.

MECHANICAL DESIGN Choice of route for the winding and accessories’ leads to
The mechanical design entails the many aspects of the the terminal boxes is also determined at this point. An
motor construction. For Ex-d type protection it innovative approach is a recessed route into the frame as
encompasses flamepaths mandated by standards to shown in Figure 9. This minimizes the risk of lead damage
eliminate flame propagation risk, as well as the explosion during assembly of motor.

Technological Developments in the Design of Electric Motors for Hazardous Areas Page 4
May 2012

Figure 11: Fin optimization


An integral, full length feet design has been shown to Cooling System
reduce vibration and ameliorate soft foot problems (Figure The cooling system comprises of motor surface area (fins),
10). It also facilitates alignment with easier use of shims. fan and fan cowl. The fan cowl shape and overall design
has a significant impact in the power absorbed by the
cooling system and therefore on motor efficiency. An
innovative design, substituting the industry standard steel
mesh by an integral and profiled cast design has decreased
passage frequencies yielding noise reductions between 3 to
11dBA.

Figure 9: Ex-d motor frame (W22Ex range courtesy of


WEG)

Figure 12: Fan cowl optimization: left industry design with


mesh, right W22EX profiled design with integral cast
mesh

Figure 10: Simulation of mechanical stresses in integral,


full length feet design.

Finite element analysis tools such as CFD are used in fin Figure 13: W22Ex fan cowl
size optimization in order to maximize thermal exchange
and distance between fins, which decreases clogging by
solid contaminants on site This innovative design was a combination of computer
simulation using CFD software and aerodynamics
engineering expertise (Figure 14). The end result is a
significantly more efficient cooling, with a reduction of
air dispersion over the frame (by 30%), noise level (3 to
11dBA) and heat (up to 100C) . Most importantly, hot
spots have been eliminated (Figure 15). These are a major
concern for hazardous areas, as they can constitute ignition
hazards. The temperature of hot spots can have a severe
impact in the maximum power rating of a given frame, its
T rating class or even the motor overall efficiency.

Technological Developments in the Design of Electric Motors for Hazardous Areas Page 5
May 2012

• Fitting of special Ex-d rated porous drain plugs


(Figure 16C) as per IEC60079-1 item 10.

Figure 14: W22Ex cooling system (green shows air flow)

Figure 16A: W22Ex DE endshield outboard view

Figure 15: W22Ex thermography showing hottest spot at


55.50C

Endshield
The endshields support the weight of the rotor and shaft, as
well as house the bearings supporting all the thrusts Figure 16B: W22Ex DE endshield inboard view
applied onto the motor by the driven equipment. In an Ex-
d type enclosure they also provide a barrier between the
internal and external environment. IEC 60079-1 item 12
prescribes the structural strength required. Together with
the fixing bolts they must withstand an internal explosion
preventing flame propagation to the external environment
(IEC 60079-1 item 5).

A detailed study of endshield and bearing retainers,


including deformation during assembly and site vibration,
as well as flame propagation analysis have prompted the Figure 16C: W22Ex DE endshield sintered drain plug
following developments in their design:
Fitting of sintered drain plug is based on a threaded joint,
• Resized and repositioned fins with a concave bearing as this was found to be safer than clamping or press-fitting
housing to reduce bearing temperature (Figure 16A). (Item 10.7 of IEC 60079-1). The plug does withstand the
• 2700 cast shroud to protect fixing bolts and prevent pressure created by an internal explosion and prevents the
water accumulation (IEC 60079-1 item 11). propagation of same to the surrounding environment,
• Casting of integral, flat vibration measuring points withstanding also the dynamic effects of explosion without
• Internal triangular bracing (Figure 16B). permanent distortion or damage as mandated by IEC
• Flush through grease lubrication (above frame 200). 60079-1 item 10.

Technological Developments in the Design of Electric Motors for Hazardous Areas Page 6
May 2012

Whereas the drive end (DE) endshield has fins which help
with heat transfer decreasing the bearing temperature, a
detailed study showed the use of a flat surface on the non
drive end endshield (NDE) yielded a significant reduction
in noise level. A smooth surface without abrupt changes in
geometric shape eliminates pressure gradients, which then
reduces noise. This is illustrated in Figures 17A and 17B.

Figure 18: W22Ex boss design angle study

In aggregate, these technological developments have also


reduced the bearing temperature around 100C to 150C. A
reduction of that magnitude permits doubling the
lubrication interval, which in the W22 range is 4 to 10
fold times longer than other designs in the market place
(Table 2).

Table 2: Lubrication Interval W22 vs. Other Designs

Figure 17A: W22Ex flat surface NDE endshield


Frame Poles Interval (hours) # Interval (hours) %
160 2 20,000 1000%
4 22,000 733%
6 22,000 733%
8 22,000 733%
180 2 15,000 750%
4 22,000 733%
Figure 17B: W22Ex NDE endshield simulation showing 6 22,000 733%
pressure gradient created by the introduction of geometric 8 22,000 733%
changes (circled area)
200 2 13,000 650%
4 22,000 733%
Both the DE and NDE endshields have an integral cast 6 22,000 733%
shroud spanning 2700 around the fixing bolts. This is a 8 22,000 733%
requirement of IEC 60079-1 (item 11) for Group I, which 225 2 4,000 400%
mandates that fixing bolts holding flamepath parts must be & 4 11,000 367%
protected against drop of foreign objects. In addition, a 250 6 17,000 567%
detailed analysis was conducted in the number of fixing
8 21,000 700%
bolts and the shape and dimension of the cast boss. The
larger the boss surface area the larger the bolt one can use 280 2 3,280 456%
to affix the endshield to the frame, and therefore the less 4 11,000 550%
number of bolts are required. On the other hand, the larger 6 15,000 500%
the boss frontal area, the more airflow it blocks having a 8 17,000 567%
significant impact on motor temperature. The boss design 315 2 3,280 456%
entails finding the optimum point between its surface and 4 9,000 450%
frontal area, which will determine the maximum bolt size,
6 13,000 433%
with number of bosses and its area of contact with the
frame. Computer simulation using finite element analysis 8 17,000 567%
(Ansys) has shown the angle with the frame has little 355 2 9,000 450%
influence on the maximum pressure the boss can 4 7,500 500%
withstand, but it assists in improving air flow. 6 10,000 333%
8 16,000 533%

Technological Developments in the Design of Electric Motors for Hazardous Areas Page 7
May 2012

Bearing Retainer grade upgrade is called for (Figure 20). The W22Ex outer
In a flameproof motor the flamepaths are a critical design bearing retainer, on the other hand, houses the mechanical
consideration as they affect directly the safety of the seal and can be replaced without interfering with
product. With that in mind, frames 71 to 200 have been flamepaths. It can also be removed to check bearing wear
redesigned with an integral internal bearing retainer or grease condition. This provides significant safety
(Figure 19B) as opposed to being a separate component improvements over existing designs, not only from a
(Figure 19A). This reduced the number of inspection product supply viewpoint, but also throughout the life of
points and product vulnerability, decreasing the number of the motor.
flamepaths between 25 and 38%, and leading to a more
robust and safer design.

Figure 20: Outer bearing retainer houses the IP type seal

Terminal Box, Blocks and Cable Fittings


The terminal box is considered a separate enclosure and
Figure 19A: Industry standard bearing retainer design as must therefore comply with all the pressure and non-
separate part transmission requirements of the frame. In addition, it
must be ample enough to house all incoming power and
accessories’ cables, provide an earthing point and proper
and safe connections (Figure 21).

Figure 21: W22Ex terminal box (low voltage range)


Figure 19B: W22Ex bearing retainer design integral to the
endshield (frames 71 to 200) The development starts by defining the gas groups the
motor should be suitable for, in this case Group IIC. This
Another innovation was on the housing of the mechanical then dictates the type of joint (cylindrical) and maximum
seal. Often motors are upgraded to a different IP grade, gap dimensions. Once the reference pressure is estimated,
say from IP55 to IP56 of IP65, to meet customer or a topological analysis using finite element analysis
application requirements. Seals also wear and need to be identifies the critical points (parts numbered 1 and 2 in
serviced from time to time. With standard endshield and Figure 22). A detailed analysis of these critical points is
bearing retainer design, these components need to be conducted (Figure 23). This is a critical step to determine
replaced by a different endshield with a different the appropriate safety factors in the design, which will
mechanical seal, say from V-ring to oil seal, when an IP

Technological Developments in the Design of Electric Motors for Hazardous Areas Page 8
May 2012

prevent the risk of an internal explosion igniting the Accurate modelling and choice of appropriate safety
surrounding environment. factors (usually 4 to 5) are crucial points in ensuring
product safety at manufacturing and throughout its life.

Auxiliary terminal boxes, for heaters and thermal sensors,


must follow the same design steps (Figure 25).

Figure 22: W22Ex terminal box lid tension vector analysis Figure 25: W22Ex main and auxiliary terminal boxes
(frames 225 to 355 low voltage)

Routing of the winding and accessories’ cables to the


terminal box is also an important design consideration
(Figure 26). This must be done in such a manner to avoid
risk of damage to cable insulation during assembly and
operation. Choice of bushings (Figure 27) and an
intermediary base allow the motor to be serviced without
messy and vexed resin manipulation.

Figure 23: W22Ex terminal box lid detailed tension vector


analysis

Should there be an internal explosion, its forces will


traction the terminal box bolts exerting a high mechanical
stress onto the bolts and bolt holding points. This is shown
in orange in Figure 24.

Figure 26: W22Ex routing of winding cables via safety


bushings

Figure 24: W22Ex terminal box tension vector analysis Figure 27: W22Ex bushings (low voltage range)

Technological Developments in the Design of Electric Motors for Hazardous Areas Page 9
May 2012

For high voltage motors, the terminal box (Figure 28A)


must meet additional requirements, which are generally
called for by international consulting firms and Oil & Gas
companies (Figure 28B). The most common are:

 Fault rating of 40kA 0.2s


 Phase segregated box
 Ability to have surge capacitors or PD couplers
installed.

Figure 29: W22Ex frames 225-355 re-greasing facilities

Figure 28A: W22Exd HV terminal box fault rated to 45kA


0.25s

Figure 28B: W22Exd HV terminal box for surge Figure 30: W22Ex frames 160-200 re-greasing facilities
capacitors, surge arresters or PD couplers

RE-GREASING
As for safe area motors, the ability to re-grease an electric
motor on the run has proven to save thousands on on-going
maintenance and downtime costs. Naturally the design
choice must comply with prevailing standards. Using the
outer bearing retainer as the grease inlet and grease outlet
(Figures 29 and 30) as opposed to the endshield has
allowed for a more robust endshield design, as well as for
the ease and full inspection of greasing facilities in situ.
This is an important improvement from a maintenance
viewpoint.
Figure 31: W22Ex HV motor with sleeve bearing
Sleeve bearings (Figure 31) have an inspection point
which permits the periodic check of oil level. Lubrication
intervals are generally much longer than grease filled anti-
friction bearings. Oil is added as needed via a side entry.

Technological Developments in the Design of Electric Motors for Hazardous Areas Page 10
May 2012

TESTING
There are a plethora of tests mandated by the relevant
sections of IEC 60079 series of standards. The most
critical are the determination of explosion pressure,
overpressure, non-transmission and thermal tests, which
are conducted by the certifying bodies. This section
focuses instead on the impact and hydrostatic tests used as
design and quality control tests.

Impact Test
The fan cowl in particular must withstand 20J of impact
energy without deformation that can create a spark hazard
by rubbing of the fan. This is even more critical for Gas
Group I. The first step is a computer simulation (Figure
32), generally using finite element analysis, and a
subsequent practical test with sensors to measure the
impact forces (IEC 62262) by dropping a 1kg probe from
2m height.

Figure 34: WEG hydrostatic testing machine used as part


of production line

CERTIFICATION & SPECIFICATIONS


Choice of certification schemes and certifying bodies is
generally made before commencement of design. The
IECEx scheme offers many advantages. But certification is
Figure 32: Fan cowl impact test simulation
only the beginning. A global supplier must also carefully
analyse the additional requirements of major Oil & Gas
companies (Shell, Chevron Texaco, Caltex, Total,
Hydrostatic Test
Aramco, Sasol, Santos, Woodside) which generally have
This test aims at verifying the mechanical strength of
their own specifications over and above the applicable
frames, endshields and terminal boxes. It is conducted at
standards. Compliance with industry associations such as
design stage, as well as an on-going quality control test to
the American Petroleum Institute (API), e.g. API 541 &
verify the quality of the castings. The motor is fitted with
547, may also need to be taken into account. In addition,
various strain gauges to measure the forces applied and
engineering firms such as Bechtel, Worley Parsons,
any deformation (Figure 33). Then it is sealed and
Technip, Clough and SKM have their own specifications,
pressurised with water (Figure 34).
which generally require special mechanical designs such
as terminal boxes with PD couplers and high short-circuit
rating.

Having defined all specifications a product range will


meet, finalised the design, tested and obtained
certification, the product range is now ready for launch.

Figure 33: Hydrostatic testing

Technological Developments in the Design of Electric Motors for Hazardous Areas Page 11
May 2012

Figure 35: W22X Ex-d IEC560 frame design

CONCLUSIONS
The design of an Ex range of motors has become a more which range to 4,500kW and 11,000V, have resulted in
vexed and challenging task given the requirements of countless practical benefits such as reduction of bearing
modern hazardous area standards and the superposition of temperature by about 100C; noise level abatement of 3 to
general standards, such as IEC 60034-30 or AS1359.5. 11dBA; safer winding and accessories’ cables routing to
Combined, these define a new realm of constraints which main and auxiliary terminal boxes, which are carefully
impact both the design and the use of Ex-rated motors. reinforced around their stress points; optimised fin
dimensions to minimise chances of clogging; bearing
High efficiency motors have invariably higher locked and selection and temperature to increase lubrication interval
inrush currents. This affects their permissible number of between 5 to 10 fold that of current designs; flat feet to
starts per hour, as well as requires higher instantaneous decrease vibration, soft foot and facilitate on-site
current rating of motor protective circuit breakers. Such alignment; quantity, shape and dimensions of bolt fixing
motors generally have lower locked rotor and breakdown points to increase safety and reduce cooling loss;
torques, which diminishes their ability to cope with altogether resulting in a cooler, quieter, high torque, high
voltage fluctuations, momentary load increases and high efficiency, ease to use and maintain, safer Ex-d electric
inertia loads. The use of inverters or VSDs in hazardous motor range.
areas continues to be clouded with uncertainty. The
requirements of the current IEC Technical Specifications In conclusion, experience and know-how, as well as
60034-17 and 60034-25 are not normative, but rather manufacturer’s approach to safety, are essential in
technical guidelines. Australia Standards Limited has capturing engineering advancements into tangible benefits
neither published standards, nor technical guidelines, to to users and the community at large. At all points
address specific requirements for motors suited for use throughout the design process the manufacturer is
with inverters. presented with a plethora of choices, which invariable
impact design time and cost, as well as product user
Mechanically, frames, endshields, bearing retainers, friendliness, efficiency, reliability and safety.
terminal boxes and blocks, cable fittings and cooling
system can benefit greatly from modern computational
tools such as Ansys and CFD. Engineering expertise in the
design of W22X range of low and high voltage motors,

Technological Developments in the Design of Electric Motors for Hazardous Areas Page 12
May 2012

WEG Technical Note 7, ‘Practical Guide for Using


ACKNOWLEDGEMENTS CFW09 Inverters and WEG Motors With Long Motor
The authors acknowledge the assistance of our colleagues Cables’, WEG, Brazil, 2005
Mr. Rafael Beck and Mr. Cassiano A. Cezario for their
useful comments in revising this paper. Yin, W; Bultemeier, K; Barta, D; and Floryan, D.
‘Dielectric Integrity of magnet wire insulations under
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Technological Developments in the Design of Electric Motors for Hazardous Areas Page 13

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