Eletric Motors

Electric motors overview
Presented by
Sylvie K. Duhaime
Emerson Motor Technologies
This document, and more, is available for download from Martin's Marine Engineering Page - www.dieselduck.net
Agenda
y Motor introduction
y Motor applications
y Electric Motor life cycle costing
y Efficiency and Motor Repairs
y Emerging
E
Motor
M
Technologies
T h l
AC Induction Motor
This is the most common place motor.
1894
Induction
M t
Motor.
Worlds
largest when
new 65 HP
new.
First
Induction
Motor, 1888
Inventor
Nikola Tesla
T d
Today
Motor parts
Frame
Fan Cover
Rear End Shield

Bearing
Front End Shield
Rotor
Shaft
Fan
Conduit Box
Stator
Laminations
Winding
Industry Standards
y National Electrical Manufacturers Association (NEMA)
y Underwriters
Underwriters Laboratories (UL))
y Canadian Standards Association (CSA) (ACNOR)
y International:
y International Electrotechnical Commission (IEC)
y Commission lectrotechnique Internationale (CEI)
y Japanese Internationall Standard
d d (JEC)
y Institute of Electrical and Electronics Engineers(IEEE)
1 HP
1 HORSEPOWER = 33,000 lbs-ft. Per minute
1 HORSEPOWER = 33,000 lbs-pi. PAR MINUTE
Motor Selection Typical information

HP
Always defined
Standardized
Frequency
60 HZ or 50HZ
May be defined from the requested speed
Speed
Defined in RPM
or
Defined if Customer provides number of

poles of the motor and power supply
f
frequency.
Voltage
Customer specification
# of phase
To be specified
by end user or
consultant
Assumed
Protection/
enclosure
To be specified
p
by end user or
consultant
575v Always Three Phase.

230/460v Always Three Phase
230v May be Three or single Phase !!!
115/230v Always single Phase
115v Always single Phase
Motor Selection
Typical Information
Standard By
Default
Comments
Environment
(Enclosure)
TEFC ( horizontal)
If otherwiset,
otherwiset the customer should
specify ODP or Explosionproof..etc..
Mounting
Horizontal Footed F1
Defined by the the letter(s) following

the frame size:
Ex: 56, 182T, 286T.
If customer specify feet and flange
the motor frame will change :
Ex: 56C, 182TC, 286TC.
Efficiency
High Efficiency ( for

60HZ)
Motor legislated by NRCan (National

Resources Canada) or Epact in the
USA ( California NEMA Premium))
Motor Coupled to
Load
Direct
If a belt pulley coupling is required

Above 75 HP Roller Bearing may be
required.
Criteria
In doubt, ask the engineer or end user!

Standard by Default
Criteria
Comment
40C
Some motors may have to

operate in higher ambient
temperature. Re-rating/sizing
available
Altitude
0 to 3300 ft (1000m)
A specific application may be

higher than3300 Ft.
De-rating /sizing available
Nema Design
g
Letter
Design
g B
If a specific application is
mentioned, select the adequate
motor (Chipper, Crusher..)
Operating Cycle
Time
S1 (Continuous)
Some applications may require

only intermittent duty
(S230
(S230mn)
)
Ambient
Temperature
ODP
Open Drip Proof (ODP)
The ODP motor has a free exchange

g or air with the
ambient.Drops of liquid or solid particles of a certain size do not
interfere with the operation at any angle from 0 to 15 downward
from the vertical.
TEFC
Totally Enclosed Fan Cooled (TEFC)
The
The TEFC type enclosure prevents free air exchange but still
breathes air. A fan is attached to the second shaft and pushes
air over the frame during operation to help in the cooling
process.
TENV-TEAO
Totally Enclosed Non-Ventilated (TENV-TEAO)
The
The TENV enclosure does not utilize a fan for cooling - but is used
in situations where air is being blown over the motor shell for
cooling.
TEXP
Explosion-Proof (TEXP)
The Explosion
p
p
proof type
yp motor is totally
y enclosed and designed
g
to
withstand an explosion of a specified gas or vapor inside the motor
casing and prevent the ignition outside the motor by sparks,
flashing, or explosion.
WPI and WPII

WPI & WPII
These are modified ODPs, with filters, screens, guarded pipevent,

t etc.
t
Other protections
z
TEWAC
TEWC
TETC
IP55 and IP 56
for IEEE841
((See IEC table))
IEC Protection digits

1st Number
2nd Number
3rd Number
Against the solid particles
Against the liquids
Against the chock
IP
Definition
IP
Definitions
IK
Non protected
Non protected
00
Non protected
dia. 50 mm
vertical drop
01
0,15J
dia. 12 mm
Drop fall at 15 from Vertical
02
0,2J
dia. 2,5 mm
Drop fall at 60 from Vertical
03
0,37J
dia. 1 mm
Drop fall at 360
04
0,5J
Dust without danger
Water jet at 360
05
0,7J
High pressure water at 360
06
1J
immersion from 0,15 to 1 m
07
2J
immersion under pressure
08
5J
09
10J
10
20J
Example: IP55
Definition
Standardized Frame (TEFC)

3600
RPM
NEMA
Program
HP
1
1.5
2
3
5
7.5
10
15
20
25
30
40
50
60
75
1800
ORIG.
1952
1964
Revision Revision ORIG.
203
204
224
225
254
284
324
326
365S
4045
405S
444S
445S
504S
203
204
224
225
254
284
324
326
364
365
404
405
444S
445S
504S
182
184
184
213
215
254U
256U
286U
324U
326S
364US
365US
405US
444US
143T
145T
182T
184T
213T
215T
254T
256T
284TS
286TS
324TS
326TS
364TS
365TS
1200
1952
1964
Revision Revision ORIG.
182
184
184
213
215
254U
256U
284U
286U
324U
326U
364U
365US
405US
444US
143T
145T
145T
182T
184T
213T
215T
254T
256T
284T
286T
324T
326T
364T
365T
204
224
225
254
284
324
326
364
365
404
405
444
445
504
505
1952
Revision
1964
Revision
184
184
213
215
254U
256U
284U
324U
326U
364U
365U
404U
405U
444U
445U
145T
182T
184T
213T
215T
254T
256T
284T
286T
324T
326T
364T
365T
404T
405T
NEMA Design Letter

In order to promote standardization, minimum acceptable values
for different motor designs
g have been established by
y NEMA.
The standardized designs are identified by the letters A, B, C,
and D.
Torque Characteristics
LRT = Lock rotor Torque,
Torque LRA= Lock rotor Current
Design A (and Design E)
Brief heavy overloads,

such as an injection
molding machine
Generall purpose
G
applications, most
common, standard
Starting heavy loads.

Applications like a
crusher
High slip, such as a low

speed punch press with a
heavy flywheel, or
h i ti applications
hoisting
li ti
Normal Starting Torque

High Starting Current
z
Design B
Low Starting Current
Design C
Low
L
St
Starting
ti C
Currentt
Design D
High Starting Torque
Low Starting Current/
High Slip
What is a motor Efficiency ?

Heat rejection ,
motor losses
Definition:
Useful power
output divided by the total
power input.
input Motor
output is the mechanical
power delivered by the
shaft - the shaft torque
times the speed (rpm)
Output: To
provide
id
work, the
motor needs
KW
Input :Power,
KW drawn
from power
supply to
operate
Efficiency is defined as the ratio of the power output by the power input
Efficiency
y Calculation
It can be calculated as follows:
Efficiency =
Output
---------I
Input
t
Efficiency
y =
HP x 746
-----------------------KW Input x 1000
Input Power - Losses

-----------------------------I
Input
tP
Power
Example: At 10 HP Load
Efficiency =
10 x 746
-------------- = .83
8.8 x 1000
Estimated annual savings on a 100HP
The Nameplate
Electric motor applications

pp
100 tons crane
Myrtle in Gulf
Pumps on a barge
25 Tons crane
Variable frequency drive
Barge Crane
Electric Motor Life Cycle Costing

DOE 2004 Industrial Energy Savings Roadmap
Purchase
P
h
C
Costts
3%
Energy Costs
88%
Installation Costs
<1%
Maintenance Costs
6%
Other Costs
3%
Assumes 100 hp
p motor,,
5,000 hours/year,
10 year life, $0.05/kWh

y Energy cost
y Maintenance cost
y Purchase cost
y Installation cost

y Down time cost
y Removal and re installation cost
y Repair cost
y Lost of efficiency cost
y Spare storage cost

And a pain in the neck
Motor facts
y Industrial motors can have a 20 to 30 year service life
y The average
a erage IHP motor is repaired 3 or more times in its
it s life [
source EASA ]
y The average IHP motor uses 4 to 6 times its original cost in
electricity per year
y Epact & NR Canada regulations cover less than 65% of motors
sold today
y Environmental
E i
t l groups estimate
ti t over 5 million
illi units
it are repaired
i d
or replaced by used each year
Efficiency
y of Repaired
p
Motors
Does it Change? Why?
y
y
y
y
y
y
Limited data available

Seven case studies (77 motors) reported efficiency
decreased between 0 to 2.5% after repair.
Average is .5 to 1% (8 to 10% increase in losses).
Efficiency degradation lower for large hp motors.
Efficiency is rarely increased.
Efficiency can be maintained over multiple rewindings
with quality repair.
3
1
Motor efficiencies for 100 hp (75 kW)

motors - typical performance curves over normal load range
E
Efficienc
cy, %
96
95
94
6 pole
6-pole
93
92
9
91
90
25
50
75
Load - % of rated
100
Some factors reducing motor life

y Working environment
Some factors reducing

g motor life
y Poor alignment, vibration
y Voltage too low and/or too high
y Excessive overload
y Ambient Temperature
y Air flow obstruction, dirty filters
y Foreign material inside the motor
y Inadequate motor selection for a specific application
IEEE 841 Plus motor cost Savings
IEEE 841+ Type CE

Severe Service Motor
z
z
Exceeds IEEE 841 1994/2001 Specs

Specs.
Meet NEMA MG1 Part 31 for inverter fed motor insulation
system.
10:1 Variable Torque, 5:1 Constant Torque
L-10 Bearing Life greatly increased
50,000 Hours on belted loads
100,000 Hours on Direct connected loads
Fi year warranty
Five
t on sine
i wave power
36 April 19 2009Emerson
Confidential
Severe Service Motor

IEEE 841 Pl
Plus T
Type CE F
Features
t
Some additional features :
y Meet NEMA Premium Efficiency Values
y Inpro VBXX bearing isolators at each end from frame 143 to 449
included as standard.
standard
y SKF CARB Toroidal Bearing (1996) option available.
y Precision balance to 0.05 IPS or better
y Same size bearing up to frame 400.
400
One motor can spare ANY application
Better
Inpro/Seal VBX
Best
Inpro/Seal VBXX
The Inpro/Seal VBX Bearing Isolator consists of two parts, a rotor and a stator, assembled into a single unit and
axially locked together by an O-ring insert. The rotor, driven by a tightly fitting drive ring is fixed to and revolves with
the shaft. The stator, a stationary component is press fitted to the bearing housing with an O
O-ring
ring gasket.
The new and improved Inpro/Seal VBXX Bearing Isolator is the latest and best technology in non-contacting
labyrinth seals. The VBXX combines the best interface for contaminant exclusion with the tried and proven VBX
Vapor Blocking O-ring.
The end result is a bearing isolator with upgraded design features, advantages and benefits that provide levels of
protection previously unavailable in any kind of bearing protection device.
The Robust motor bearing design

with
ith CARB
Ball Bearing
CARB Bearing
y Ideal
Id l ffor:
y Belt drives
y Very high loads
y Misalignment
Allows for:
y Direct drives
y Shaft bending
Short End
Pulley End
Epoxy Coated Rotor
.05IPS 360 frame

.08IPS 140-320 frame
VBXX Inpro
Seals
Internal
Bearing
Caps 180
Inverter Grade
Insulation
NEMA Part 31
B
Brass
B th D
Breather
Drains
i
US Motors 841 Plus

New technology : system solution
Permanent Magnet Synchronous Motor
Bow Thrusters Propulsion motors
Vi it our web
Visit
b sites
it
www.usmotors.com
www.leroysomer.com
Available training online


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Electric motors overview

Rear End Shield

Front End Shield

Motor Selection Typical information

May be defined from the requested speed

Defined if Customer provides number of

575v Always Three Phase.

Defined by the the letter(s) following

High Efficiency ( for

Motor legislated by NRCan (National

If a belt pulley coupling is required

In doubt, ask the engineer or end user!

Some motors may have to

A specific application may be

Some applications may require

The ODP motor has a free exchange

WPI and WPII

These are modified ODPs, with filters, screens, guarded pipevent,

((See IEC table))

IEC Protection digits

Against the solid particles

Against the liquids

Against the chock

Drop fall at 15 from Vertical

Drop fall at 60 from Vertical

Drop fall at 360

Dust without danger

Water jet at 360

High pressure water at 360

immersion from 0,15 to 1 m

immersion under pressure

Standardized Frame (TEFC)

NEMA Design Letter

Design A (and Design E)

Brief heavy overloads,

Starting heavy loads.

High slip, such as a low

Normal Starting Torque

What is a motor Efficiency ?

Input Power - Losses

Estimated annual savings on a 100HP

Electric motor applications

100 tons crane

Electric Motor Life Cycle Costing

Electric Motor Life Cycle Costing

Electric Motor Life Cycle Costing

Electric Motor Life Cycle Costing

Limited data available

Motor efficiencies for 100 hp (75 kW)

Some factors reducing motor life

Some factors reducing

IEEE 841 Plus motor cost Savings

IEEE 841+ Type CE

Exceeds IEEE 841 1994/2001 Specs

Severe Service Motor

One motor can spare ANY application

The Robust motor bearing design

Epoxy Coated Rotor

.05IPS 360 frame

US Motors 841 Plus

New technology : system solution

Permanent Magnet Synchronous Motor

Bow Thrusters Propulsion motors

Available training online