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Technological Developments in the Design of Electric Motors for Hazardous Areas Page 1
May 2012
Torque-Locked Rotor
these have on the motor electrical design for hazardous 2.0
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
= ∫ = = ( )
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.
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.
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
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
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).
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.
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.
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.
Figure 22: W22Ex terminal box lid tension vector analysis Figure 25: W22Ex main and auxiliary terminal boxes
(frames 225 to 355 low voltage)
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
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.
Technological Developments in the Design of Electric Motors for Hazardous Areas Page 11
May 2012
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,
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May 2012
Technological Developments in the Design of Electric Motors for Hazardous Areas Page 13