1

MOTORS - AN OVERVIEW

1. GENERAL CONSIDERATIONS: -

A DETAILED UNDERSTANDING OF TYPE OF MOTORS, MOUNTING, ENCLOSURES, DUTY

HELPS IN IDENTIFYING APPROPRIATE TYPE OF MOTOR FOR THE INTENDED
APPLICATION. A LARGE POPULATION OF MOTORS RIGHT FROM FRACTIONAL HORSE
POWER TO MOTORS UPTO 12 MW ARE IN USE IN VARIOUS INDUSTRIES.

THIS COVERAGE IS PRIMARILY FOCUSED FOR RATINGS ABOVE 150 KW WHERE

APPLICATION, MOUNTING ARRANGEMENT, ATMOSPHERIC CONDITIONS PLAY A MAJOR
ROLE. IT IS ESTIMATED THAT YEARLY DEMAND OF MOTORS RANGING FROM 150 KW
ONWARDS IS ROUGHLY 1200 TO 1500 EACH YEAR.

MAJOR PLAYERS IN THE INDIAN CONTEST ARE

1) BHEL…WHOSE MARKET SHARE IS APPROXIMATELY 70% FOLLOWED BY
2) CGL, KEC AND OTHERS.

2. MOTORS CLASSIFICATION: -

A) CLASSIFICATION BASED ON TYPE: -

A1) A.C INDUCTION MOTORS

A) SQUIRREL CAGE INDUCTION MOTORS

B) SLIP RING INDUCTION MOTORS
C) VARIABLE SPEED DRIVES INDUCTION MOTORS WITH 2 OR 3 WINDINGS FOR
DIFFERENT SPEEDS. 2 WINDING MOTORS WILL GIVE 4 SPEEDS (2 DIFFERENT SPEEDS
FOR EACH WINDING WITH STAR AND DELTA CONNECTION)

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 2

A2) DIRECT CURRENT MOTORS: -

A) WITH SERIES FIELD WINDING

B) WITH SHUNT FIELD WINDING
C) WITH COMPOUND FIELD WINDING HAVING SHUNT AS WELL
AS SHUNT WINDING.

A3) SYNCHRONOUS MOTORS

A) ASYNCHRONOUS MOTORS HAVING SLIP RING WINDING

ALONGWITH DC FIELD WINDING
B) SYNCHRONOUS MOTORS WITH DAMPER BAR WINDING AND DC FIELD WINDING.
THESE CAN BE EITHER

B1) SALIENT POLE CONSTRUCTION

B2) CYLINDRICAL ROTOR CONSTRUCTION.

C) VARIABLE FREQUENCY DRIVES.

B) CLASSIFICATION BASED ON MOUNTING: -

B1) HORIZONTAL MOUNTING

ALL GENERAL PURPOSE MOTORS FOR CONVEYER, CRUSHER, COMPRESSOR, ID FAN,
PA FAN, SECONDARY AIR FAN, EXHAUST, AND SIMILAR APPLICATION SUCH MOTORS ARE
IN COMMON USE.

B2) VERTICAL MOUNTING

THESE ARE GENERALLY USED FOR PUMP APPLICATION, SCREW DOWN APPLICATION,
OR VERTICAL BORING, ON BOARD DRILL APPLICATIONS. SOME TIMES FOR PUMPS
HORIZONTAL MOTORS ARE ALSO IN USE.

B3) SPECIAL MOUNTING APPLICATIONS: -

REQUIRING SUITABILITY TO OPERATE AT AN ANGLE SAY FOR SUBMARINE OR
FRIGATE APPLICATIONS. THIS REQUIREMENT IS CALLED SWING /RANGE. THESE MOTORS
ARE ALSO REQUIRED TO BE SUITABLE FOR RESISTANCE TO HEAVY SHOCKS GENERATED
DUE TO SHELLING OF EXPLOSIVES . (A SHOCK LEVEL OF 7G) MAY BE REQUIRED WHICH
IN LAYMANS TERMS CAN BE CONSIDERED EQUIVALENT TO FALLING OF AN
EQUIPMENT FROM A HEIGHT OF 9 METERS FROM THE GROUND AND AFTER WHICH
THE EQUIPMENT SHOULD STILL BE ABLE TO PERFORM FOR ITS INTENTED DUTY)

OTHER APPLICATIONS ARE TORPEDOES, GUN CONTROL ETC WHERE SUCH SPECIAL
PURPOSE MOTORS ARE REQUIRED. THIS CATEGORY ALSO INCLUDE SPECIAL PURPOSE
MOTORS REQUIRED FOR BATTLE TANKS. THESE ARE TOTALLY ENCLOSED MOTORS
PROVIDED WITH SPECIAL BEARINGS. THESE MOTORS ARE REQUIRED TO SWING
UPWARD DOWNWARD AND AT DIFFERENT ANGLES TO VERTICAL AXIS.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 3

C) CLASSIFICATION BASED TYPE OF ENCLOSURE: -

TYPE OF ENCLOSURE WILL DEPEND UPON THE ENVIRONMENT IN WHICH THE

MOTOR IS
REQUIRED TO OPERATE
.
C1) AN IP 23 –SPDP/DP TYPE MOTOR CAN BE USED IN A CLEAN ATMOSPHERE FREE OF
DUST, AND NON-HAZORDOUS ATMOSPHERE SAY IN THE POWER HOUSE OR CLEAN
WORK SHOP. THE HEAT TRANSFER FROM HOT PARTS OF MOTOR TO THE ATMOSPHERE
IS BY CONVECTION PROCESS. THE PROCESS INVOLVES ENTRY OF AIR FROM ONE END
AND EXIT AT OTHER END. GENERALLY AIR INTAKE IS FROM NON-DRIVE END AND
OUTLET IS FROM DRIVE END.

C2) IP 44 DUCT VENTILATED MOTOR

IN THIS TYPE OF CONSTRUCTION, INLET AIR IS FED TO THE MOTOR AT NDE SIDE
THROUGH A DUCT. AT THE BIGGENING OF DUCT A POWERED FAN IS PROVIDED WHICH
FORCES FRESH ATMOSPHERIC AIR INTO THE DUCT. OUT LET AT DE SIDE IS EITHER
THROUGH DUCT OR RELEASED IN THE MOTOR SURROUNDING.

FOR MULTI SPEED MOTORS WITH CONSTANT TORQUE APPLICATION, EXCEPT

FRICTION AND WINDAGE LOSSES (WHICH ARE PROPORTIONAL TO SPEED), OTHER
LOSSES REMAIN CONSTANT NEEDING SAME AMOUNT OF AIR AT ALL SPEEDS FOR
EFFECTIVE COOLING. FOR SUCH ARRANGEMENT THIS TYPE OF DUCT VENTILATED
COOLING IS BEST PROPOSITION PROVIDED THE SURROUNDING ATMOSPHERE IS CLEAN
AND NON HAZARDOUS.

C3) IP54 PROTECTION MOTORS ARE TEFC/TETV/CACA/OR CACW ENCLOSURE MOTORS,

WHICH ARE EXTENSIVELY USED FOR HUMID, DUSTY, AND CONTAMINATED AIR
ATMOSPHERE. THE COMMON TYPE IS: -

C3.1) TETV /TEFC (IP54/IP55 CLASS OF PROTECTION): -

CALLED TOTALLY ENCLOSED TUBE VENTILATED OR TOTALLY ENCLOSED FAN

COOLED. THE INSIDE OF THE MOTOR IS CIRCULATED FROM INSIDE OF MOTOR
TO THE SPACE (OR SHELL) WHICH HOUSES TUBES. THE HEAT OF INSIDE AIR IS
TRANSFERRED TO THE TUBES BY CONDUCTION PROCESS THE OUTSIDE AIR IS
FORCED THROUGH THESE TUBES BY FANS MOUNTED ON OUTSIDE PORTION OF
THE MOTOR. THE TRANSFER OF HEAT THROUGH THESE TUBES IS BY PROCESS
OF CONVECTION.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 4

BLOCK DIAGRAM OF A HORIZONTAL TETV MOTOR

TOTALLY ENCLOSED TUBE VENTILATED (OR ALSO CALLED TOTALLY ENCLOSED FORCED
COOLED MOTORS ARE BEST SUITED FOR DUSTY/HUMID & SALINE ENVIRONMENT.
THE SECTIONAL LAYOUT OF THE MOTOR BELOW SHOWS VARIOUS MAJOR PARTS AND
COOLING TUBE ARRANGEMENT.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 5

HERE THE TWO INTERNAL FANS CIRCULATE THE INTERNAL BETWEEN ROTOR AND WOUND
STATOR THROUGH THE SHELL IN THE FABRICATED FRAME. WHILE EXTERNAL FAN TAKES
SURROPUNDING OUTSIDE AIR AND PUSHES THROUGH THE COOLING TUBES HOUSED IN THE
FABRICATED FRAME.

SINCE IN THIS TYPE OF CONSTRUCTION COOLING TUBES ARE HOUSED ALL AROUND THE
WOUND STATOR CAPSULE, THE COOLING IS EFFECTIVE. THESE MOTORS HAVE HIGHER
ORDER OF EFFICIENCY COMPARED TO CACA OR TOTALLY ENCLOSED TYPE CONSTRUCTION
MOTORS.

C3 .2) CACA TYPE INDUCTION MOTORS

THESE MOTORS ARE PROVIDED WITH TOP OR SIDE MOUNTED AIR TO AIR HEAT
EXCHANGERS. EQUIPMENT HOT INSIDE AIR PASS THROUGH THE COOLER SHELL AND
HEAT TRANSFER TAKES PLACE THROUGH HEAT EXCHANGER TUBES WHICH CARRY
SURROUNDING ENVIRONMENTAL COOL AIR.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 6

THE DIFFERENCE BETWEEN TETV AND CACA MOTORS IS THAT, IN CASE OF TETV/TEFC
MOTOR THE COOLER TUBES ARE SURROUNDED ALL OVER THE WOUND STATOR, WHILE IN
CASE OF CACA MOTORS, THE TUBES ARE HOUSED IN TOP MOUNTED COOLER.

FOR THE SAME RATING AND SPEED CACA MOTORS WILL HAVE LESS SHAFT CENTRE HEIGHT
COMPARED TO TETV OR TEFC MOTORS. THEREFORE WHERE EVER SHAFT CENTRE HEIGHT
IS LIMITATION, ONE CAN GO FOR CACA MOTORS.

REGULAR CLEANING OF COOLER TUBES IN BOTH CASES IS ESSENTIAL DURING ROUTINE

MAINTENANCE SINCE ACCUMULATION OF DUST AND SCALE FORMATION MAY REDUCE
HEAT TRANSFER CAPABILITY OF COOLER RESULTING REDUCED PERFORMANCE AND
HIGHER TEMPERATURE RISE OF THE MOTOR.

IP54/IP55 MOTORS WITH SPEED VARIATION.

SINCE BOTH TETV OR CACA MOTORS HAVE SHAFT MOUNTED FAN FOR EXTERNAL AIR
CIRCUIT, WHERE EVER SPEED VARIATION IS INVOLVED, AT REDUCED SPEED ONLY
FRICTION LOSSES WILL REDUCE WHILE LOAD LOSSES WILL PRACTICALLY REMAIN SAME.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 7

AT REDUCED SPEED VELOCITY OF INTERNAL CIRCULATING AIR AS WELL AS EXTERNAL

CIRCULATING AIR WILL REDUCE WHICH WILL AFFECT HEAT TRANSFER RESULTING HIGHER
TEMPERATURE RISE THEN PERMISSIBLE. THIS WILL EFFECT ON MOTOR PERFORMANCE. IN
SUCH CASE BLOWERS ARE PROVIDED ON THE COOLERS WHICH OPERATE ON SEPERATE
230/415 VOLTS SUPPLY.

THUS BARING REDUCTION IN CAPACITY DUE TO REDUCED INTERNAL AIR CIRCULATION,

THE MOTOR (S) CAN OPERATE AT LOWER SPEEDS ALSO GIVING SAME PERFORMANCE.

TOTALLY ENCLOSED MOTORS (IP55/IP54 PROTECTION)

THE MOTORS OF SMALLER RATINGS SAY UPTO 250 KW CAN BE OFFERED IN TOTALLY
ENCLOSED FRAMES. THE FRAMES ARE GENERALLY OF ROUND CONSTRUCTION (CAST OR
FABRICATED) SINCE HEAT GENERATED DUE TO MOTOR LOSSES IS POSSIBLE TO DISSIPATE
THROUGH ONLY STATOR FRAME, THE STATOR FRAME IS PROVIDED WITH LARGE NO OF
FINS TO INCREASE HEAT TRANSFER SURFACE AREA. THIS TYPE OF CONSTRUCTION IS
COMMONLY KNOWN.

THESE MOTORS ARE MOST SUITED WHERE OPERATIONS ARE SUBJECTED TO OPEN
ATMOSPHERE HAVING NO SHADE (E.G. PUMP HOUSES/ EXCAVATION/ MUD COLLECTORS
ETC).

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 8

C3.3) INCREASED SAFETY

SUCH TYPE OF MOTORS ARE REQUIRED WHERE TYPE E PROTECTION IS
REQUIRED. PRIMARILY THESE MOTORS CAN BE TETV/TEFC/CACW/CACA
TYPE BUT JOINTS AND MATCHING PARTS SHOULD BE PERFACT TO AVOID
ANY CHANCE OF INGRESS OF OUTSIDE AIR TO COME IN CONTACT WITH
INSIDE AIR OF THE MOTOR

C3.4) FLAME PROOF MOTORS/PRESSURISED ENCLOSURE

THESE ARE SPECIAL PURPOSE MOTORS, USED IN INFLAMABLE AREA OF
OPERATION SAY GAS /OIL PRODUCING UNITS WHERE A LITTLE SPARK CAN
RESULT GENERATION OF FIRE DUE TO HAZORDOUS ATMOSPHERE PRONE
TO FIRE. THESE MOTORS USE EVEN ALL TERMINAL BOXES/AUX BOXES
WHICH IS FLAME PROOF. EACH AND EVERY MOTOR IS REQUIRED TO BE TESTED AT
CMRI/DHANBAD FOR ASCERTAINING ITS WORTHYNESS FOR WORKING IN SUCH
ATMOSPHERE.

WHERE EVER FLAME PROOF MOTORS ARE NOT POSSIBLE TO SUPPLY (SAY IN CASE
OF LARGE RATINGS, OTHER WAY IS TO PRESSURISE THE ENCLOSURE OF THE
MOTOR. THIS CONSIST OF OPERATION OF MOTOR WITH INSIDE PRESSURE HIGHER
THEN OUT SIDE ATMOSPHERIC PRESSURE SO THAT OUTSIDE INFLAMABLE GASES DO
NOT ENTER INTO THE MOTOR (SINCE MOTOR INSIDE PRESSURE IS HIGHER) FOR
SUCH SYSTEM SPECIAL PURGING UNITS ARE FITTED ON THE MOTOR WHICH ARE
PREFERRED TO MECHANICALLY OPERATED (FOR AVOIDING ANY SPARKS ETC) AND
ONCE INSIDE PRESSURE IS ATTAINED THE BREAKER WILL MAKE ON THE SUPPLY.
PRESSURE INSIDE MOTOR IS REQUIRED TO REMAIN HIGHER THEN OUTSIDE
THROUGHOUT THE OPERATING TIME OF THE MACHINE.

C) CLASSIFICATION BASED ON SUPPLY VOLTAGE

DEPENDING ON AVAILABILITY OF SUPPLY VOLTAGE THE MOTORS CAN BE

CLASSIFIED AS
FOLLOWS: -

1) AS PER AMERICAN/EUROPEAN PRACTICE: -

A) LT RANGE MOTORS – 230 VOLTS, 415 VOLTS
B) MEDIUM VOLTAGE RANG- 690 VOLTS TO 3300 VOLTS
C) HT RANGE MOTORS – 6600 VOLTS AND 11000 VOLTS.
2) AS PER INDIAN PRACTICE: -
LT RANGE MEANS 230 VOLTS, 415VOLTS AND 690 VOLTS
AND HT MEANS 3300, 6600 AND 11000 VOLTS RANGE.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 9

D) MOTORS DUTY

E1) SHORT TIME DUTY

E2) INTERMITTANT DUTY
E3) CONTINUOUS DUTY.
GENERALLY BUYERS SPECIFY CONTINUOUS DUTY ONLY.

3 SELECTION OF MOTOR AND DEFINING SPECIFICATIONS: -

IDENTIFYING REQUIREMENTS IS REALLY A CRITICAL TASK. THIS INVOLVES: -

A) ENVIRONMENTAL CONDITIONS
B) SUPPLY VOLTAGES AND FREQUENCY & VARIATION
C) LOAD DETAILS
D) CONTROLS/SIGNALS REQUIRED FROM MOTOR INSTRUMNETS FOR
VARIOUS CONTROLS
E) OTHER STATUTORY REGULATORY REQUIREMENTS.
F) OTHER PARAMETERS (NO OF START/STOPS/LOAD CYCLE ETC)

3.1 FIRST 3 PARAMETERS BECOME THE GUIDE LINES FOR FRAMING SPECIFICATIONS
AND NEED CAREFUL CONSIDERATIONS.
A) ENVIRONMENTAL CONDITIONS INCLUDE AMBIENT CONDITIONS i.e. MAX
AMBIENT TEMPERATURE, LATITUDE AND ALTITUDE, TYPE OF ATMOSPHERE
(DUSTY/HUMID, SALINE, CHEMICALLY ACTIVE, HAZARDOUS ETC). ENVIRONMENTAL
CONDITIONS HAVE BEARING ON TYPE OF ENCLOSURE TO BE SELECTED e.g. FOR
HAZARDOUS ATMOSPHERE PRESSURISED ENCLOSURE MOTORS AND IN CASE OF
INFLAMABLE ATMOSPHERE (SAY IN REFINERY ETC) FLAME PROOF MOTORS MAY BE
REQUIRED. THE TYPE OF ENCLOSURE WILL DECIDE ABOUT THE SIZE OF THE
MOTOR AND THE COST AS WELL .

SIMILARLY HIGHER THE AMBIENT, LOWER WILL BE THE TEMPERATURE RISE

LIMITS AVAILABLE. FOR EXAMPLE, FOR A CLASS F INSULATED MOTOR, WITH AMB
CONDITION OF 20 DEG C, THE ALLOWED TEMP IS 120 DEG (WITH CLASS B LIMITS)
FOR THE WINDING THIS MEANS TEMPERATURE RISE CAN GO UPTO 100 DEG C OVER
20 DEG AMBIENT. AT SOME OTHER GEOGRAPHICAL POSITION HAVING AMBIENT OF
50 DEG C, IF FOR SAME RATING IF MOTOR IS TO BE SELECTED THEN ALLOWED TEMP
RISE WOULD BE ONLY 70 DEG C. EVENTUALLY A HIGHER SIZE MOTOR WILL BE
REQUIRED.

B) LOAD DETAILS

FROM ENERGY MANAGEMENT/CONSERVATION POINT OF VIEW LOAD DETAILS PLAY A

VITAL ROLE? IN SELECTING A MOTOR RATING. THE ACTUAL LOAD REQUIREMENT AT
DUTY POINT MAY BE MUCH LOWER THEN THE MOTOR RATING. THIS WILL RESULT IN
POOR LOADING OF DRIVE, LOWER OPERATING EFFICIENCY, AND HIGHER ENERGY
LOSSES. FOR EXAMPLE, IN A BOWL MILL (IN A POWER PLANT) THE LOAD REQUIREMENT
MAY BE OF SAY 165 KW AT DUTY POINT. HOWEVER, THE BOWL MILL SUPPLIER WILL

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 10
TAKE 20% MARGIN AND WILL INDICATE A RATING OF 198 KW. THE CONSULTANT OF
THE BUYER WILL TAKE ANOTHER 10% MARGIN ARRIVING AT A RATING OF 220 KW AND
WILL FLOAT ENQUIRY FOR ABOVE RATING. THE MOTOR SUPPLIER’S DESIGN
DEPARTMENT WILL TAKE ANOTHER SAFETY MARGIN OF 10 % AND WILL FINALLY
DESIGN THE MOTOR FOR 240 KW RATING. GENERALLY DESIGNERS DESIGN THE MOTOR
AT THIS RATING FOR OPTIMAL EFFICIENCY/POWER FACTOR.

THE RESULT IS EVEN AT 165 KW DUTY POINT (REAL REQUIREMNT) THE PERCENTAGE
LOADING WILL ONLY BY 69%. NATURALLY THIS WILL RESULT IN POOR PERFORMANCE
OF MOTOR AND HIGHER ENERGY CONSERVATION.

AS SUCH IT IS IMPORTANT ON THE PART OF BUYER/USER TO APPROPRIATELY SELECT

THE RATING TAKING ALL ASPECTS INTO CONSIDERATIONS.

C) SUPPLY SYSTEM

SUPPLY SYSTEM INCLUDES, SYSTEM VOLTAGE, FREQUENCY AND VARIATION IN

VOLTAGES AND FREQUENCY. THESE SHOULD BE STIPULATED CORRECTLY AS
THESE ARE IMPORTANT FROM THE POINT OF VIEW OF MOTOR DESIGN.

IN SOME CASES BUYERS SPECIFY 11 KV MOTOR OPERATING VOLTAGES. HOWEVER

IF POSSIBLE IT WILL BE PREFERABLE TO HAVE A STEP DOWN TRANSFORMER SO
THAT 6600 VOLTS SUPPLY IS AVAILABLE ACROSS MOTOR TERMINALS. THE REASON
IS ALMOST ALL MANUFACTURERS NOW A DAYS USE CLASS F INSULATION SYSTEM
COMMON FOR ALL VOLTAGES. BUT FOR 11 KV SYSTEMS, DUE TO INCREASED
INSULATION THICKNESS SPECIAL VPI TECHNIQUES ARE TO BE IMPLEMENTED
INCREASING THE COSTS. FURTHER 11KV WINDINGS ARE DIFFICULT TO REPAIR
ALSO.

FOR THE SAME RATING, IN GENERAL, WHILE THERE IS NO REDUCTION IN SIZE OF THE
MOTOR, THE COST OF 11KV MOTOR MAY BE HIGHER BY 10 TO 15% COMPARED TO A 6.6
KV MOTOR.

D ) OTHER PARAMETERS: -
OTHER PARAMETERS LIKE NO OF STARTS, STOPS, STARTING CURRENT LIMITATION,
AXIAL THRUST IF ANY ARE ALSO IMPORTANT FROM DESIGN POINT OF VIEW AND NEED
TO BE SPECIFIED IN THE TENDER SPECIFICATIONS.

A FORMAT OF TECHNICAL REQUIREMENTS WHICH ARE REQUIRED TO BE SPECIFIED

ARE FURNISHED BELOW WHICH COULD BE HELP FUL TO USERS WHILE RAISING
ENQUIRY TO VENDORS:-

INFORMATION REQUIRED FOR ARRANGING OFFER FOR MOTORS

NO. DESCRIPTION

1 APPLICATION

2 MACHINE DESCRIPTION

3 RATING (KW) / SYNCHRONOUS SPEED

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 11

4 SUPPLY SYSTEM PARAMETERS:-

4.1 SUPPLY VOLTAGE

4.2 VARIATION IN VOLTAGE
4.3 VARIATION IN FREQUENCY

5 TYPE OF MOTOR REQUIRED(SLP RING/CAGE/VFD)

6 MOUNTING (HORIZONTAL/VERTICAL/SPECIAL INCLINED)

7 ENCLOSURE (TETV/TEFC/CACA/CACW/SPDP/DP/DUCT VENTILATED)

8 PROTECTION CLASS (IP23/IP44/IP55)FLAME PROOF/INCREASED SAFETY

8a INSULATION CLASS / TYPE(F/B)

9 SITE CONDITIONS:-

9.1 SITE MAX AND MIN AMBIENT

9.2 HUMIDITY
9.3 TYPE OF ATOMOSPHERE(CLEAN/DUSTY/SUSTABLE TO
FIRE(INFLAMABLE GASES ETC)
9.4 ALTITUDE/LATITUDE(FROM MSL)(IF NOT FURNISHED WE WILL
ASSUME IT IS LESS THEN 1000M ABOVE MSL)

10 LOAD DETAILS

10.1 TYPE OF LOAD(CONVEYER/CRUSHER/ID FAN/PA FAN/PUMP/COMPRE-

SSOR/SCREW/MILL/ANY OTHER)
10.2 TYPE OF COUPLING(FLEXIBLE/FLUID/TRACTION/RIGID/V BELT)
10.3 LOAD CURVE IF ANY
10.4 LOAD GD SQ/INERTIA (MKSQ)

11 STARTING CONDITIONS IF ANY:

11.1 TYPE OF STARTING- DOL/SOFT STARTER/REACTANCE STARTING

11.2 STARTING CURRENT(IF NOT FURNISHED WE SHALL QUOTE MOTOR
WITH 600% FLC SUBJECT TO IS TOLERANCE)
11.3 STARTING TORQUE REQUIREMENT.

12 DETAILS OF ESSENTIAL ACCESSORIES

12.1 WINDING RTDS-PT 100

12.2 BEARING RTDS-PT 100
12.3 BEARING DIAL THERMOMETERS.
12.4 SPACE HEATERS (240 V, 1PH AC)
12.5 STATOR TB - PSTB / PH, SEP, / ELASTIMOLD / [Link]
12.6 NEUTRAL TB- PSTB / NON-PSTB WITH / WITHOUT CT MOUNTING
12.7 ROTOR TERMINAL BOX(ONLY IN CASE OF SLIP RING MOTOR)

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 12

12.8 AUXILIARY TERMINAL BOX FOR RTDS & BTDS

12.9 ANY OTHER REQUIREMENT (FOUNDATION BOLTS ETC)

RATING LIMITS FOR 415 VOLTS OPERATING VOLTAGE:-

MOTOR OPERATING VOLTAGES OF 415 VOLTS ARE SUITABLE FOR LOWER RATINGS ONLY.
FOR HIGHER RATINGS EITHER 3300 VOLTS, 6600 VOLTS OPERATING VOLTAGES ARE
PREFERABLE.

TO THE EXTENT POSSIBLE FOR HIGHER RATINGS(NORMALLY BEYOND

750KW)SELECTION OF LT (415 VOLTS OR 690 VOLTS) MOTORS SHOULD BE AVOIDED
BECAUSE MOTORS WITH SUCH LOW VOLTAGES WILL BE REQUIRED TO BE DESIGNED
WITH THICKER WINDING COPPER CONDUCTOR CROSS SECTION, REDUCING PUNCHING
TEETH WIDTH . ALSO THE THICKER COIL CROSS SECTION WILL INCREASE OVER HANG
LENGTH RESULTING OVER SIZING OF MOTOR. ALSO THERE WILL BE PROBLEMS IN
MAIN AND NEUTRAL TERMINATION THROUGH TERMINAL BOXES. SUCH MOTORS MAY
NEED HIGHER DIA CABLES WHICH MAY AGAIN BE COSTLY AFFAIR. IN GENERAL LT
MOTORS WITH CABLES/TERMINATION/BREAKERS ETC(CONSIDERING SYSTEM IN
TOTALITY) MAY BE COSTLY PROPOSITION AS COMPARED TO 3.3 KV OR 6.6 KV MOTORS.

3.2 ENCLOSURE:-

SELECTION OF ENCLOSURE WILL DEPEND ON THE ENVIRONMENTAL CONDITIONS

WHICH CAN BE CLASSIFIED AS FOLLOWS:-

@ FOR CLEAN NORMAL ATMOSPHERE –SELECTION OF SPDP/DP MOTOR WILL BE

ECONOMIC.

@ FOR DUSTY/HUMID/CONTAMINATED/ CORROSIVE ATMOSPHERE IT IS PREFERABLE

TO GO FOR TEFC/TETV/CACA OR CACW MOTORS.
IF RATING AND SIZE PERMITS AND THERE IS NO SUCH CONDITION OF LIMITATION
OF SHAFT CENTRE HEIGHT THEN IT IS PREFERABLE TO SELECT A TEFC/TETV
COMPARED TO A CACA MOTOR, BECAUSE THE COOLING TUBES ARE PLACED ALL
ROUND THE STATOR CORE PROVIDING UNIFORM COOLING THROUGH OUT THE
CORE PERIPHERY. FURTHER CG OF THE MOTOR WILL REMAIN NEAR TO THE SHAFT
CENTRE AXIS THEREBY GIVING HIGHER MOTOR STABILITY FROM GRAVITATIONAL
STABILITY POINT OF VIEW

WHEN EVER SHAFT CENTRE HEIGHT IS A LIMITATION THE OTHER ALTERNATIVE IS

TO BUY A CACA MOTOR. THIS MOTOR IS ALSO TO IP 54/55 DEGREE OF PROTECTION
BUT IN THIS CASE ALL THE TUBES (WHICH OTHER WISE ARE SPREAD THROU-OUT
PERIPHERY OF STATOR CORE) ARE BUNDLED IN THE COOLER CASING. THIS COOLER
IS MOUNTED ON TOP OF THE MOTOR. CACW ENCLOSURE IS ANOTHER VERSION IN
WHICH WATER COOLED COOLER IS PLACED ON TOP OF THE MOTOR

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 13

IN BOTH (i.e.) CACA OR CACW CONSTRUCTION MOTORS, THE FRAME IS OF

RECTANGULAR CONSTRUCTION(BOX TYPE) WITH COOLER MOUNTED ON TOP OF
MOTOR IN GENERAL FOR MOTOR OF SAME RATING, VOLTS AND SPEED, A TEFC/TETV
MOTOR WILL BE OF LARGEST SIZE, THEN A CACW/CACA MOTOR WHICH WILL BE
LARGER THEN A SPDP/DP MOTOR. INOTHER WORDS, FOR SAME FRAME, MORE
POWER CAN BE PACKED IN A SPDP/DP MOTOR AS COMPARED TO CACW/CACA AND
TEFC/TETV MOTOR.

@ FOR LARGE SIZED MOTORS TETV/TEFC MOTORS MAY NEITHER BE AVAILABLE NOR
ECONOMIC AND THEREFORE GENERALLY BUYERS GO FOR CACA/CACW MOTORS
@ FOR VERTICLE MOTORS USED FOR PUMP/DRILL/SCREW DOWN APPLICATION
IT WILL BE WORTHWHILE TO GO FOR A TETV/TEFC MOTOR HAVING COOLING
TUBES ALL ROUND THE STATOR CORE. THE ADVANTAGE OF SUCH
CONSTRUCTION IS THAT, IN TETV/TEFC CONSTRUCTION FOR VERTICAL MOTORS
CG OF THE MOTORS PASSES THROUGH THE CENTRE OF THE SHAFT RESULTING A
BALANCED OPERATION(IN CASE OF VERTICLE MOTORS PUMP AND MOTOR SHAFT
CG SHAOULD PASS IN CENTRAL VERTICAL AXIS . IN SUCH MOTORS CACA/CACW
MOTORS SHOULD ONLY BE USED IF TETV/TEFC OPTION IS NOT AVAILABLE.
BECAUSE, DUE TO ONE SIDE OF COOLER MOUNTED ON MOTOR FRAME CG OF
MOTOR WILL SHIFT AWAY FROM CENTRE OF SHAFT AND MAY RESULT VIBRATION

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 14

A TETV MOTOR FOR SUCH VERTICAL APPLICATIONS MAY HAVE

BETTER OPERATIONAL PERFORMANCE COMPARED TO A CACA MOTOR.

@ FLAME PROOF AND INCREASED SAFETY MOTORS GENERALLY WARRANT

MORE ASSOCIATION AND CONSULTATION WITH THE MANUFACTURERS, AND
THEIR SELECTION SHOULD BE ON MUTUAL DISCUSSIONS AMONG
BUYER AND MANUFACTURER..

3. TEMPERATURE RISE CONSIDERATIONS

THE MAIN CAUSE OF RISE IN TEMPERATURE IS COPPER LOSS IN WINDING

DUE TO WINDING RESISTANCE, STRAY LOAD LOSS AND NO LOAD LOSS (WHICH
COVERS FRICTION WINDAGE LOSS+CORE LOSS+ LOSS ES IN BEARINGS ).

WHILE NO LOAD LOSS IS CONSTANT FOR A ROTATING EQUIPMENT, LOAD LOSS

(WHICH IS COPPER LOSS IN THE WINDING AND STRAY LOAD LOSS VARIES WITH
THE SQ OF THE CURRENT FLOWING THROUGH THE WINDING. THIS IS THE LOSS
WHICH IS IN MAJORITY IS RESPONSIBLE FOR THE TEMPERATURE RISE OF THE
MACHINE. CONSTANT HEATING UP AND PROLONGED USE OF MACHINE RESULTS
INTO AGING OF INSULATION AND CORE OF THE MACHINE RESULTING
REDUCTION OF PERFORMANCE AND LIFE LEVELS ORIGINALLY DESIGNED/INDENTED.
THEREFORE SHOULD HAVE SUFFICIENT THERMAL RESERVES FOR
ITS PROLONGED CONSISTANT PERFORMANCE BY AND LARGES MODERN
PRACTICE IS TO PROVIDE CLASS F INSULATED MOTORS( WITH ROLL
IMPREGNATION OF VACCUM PRESSURE IMPREGNATION). HOWEVER IT IS IN
THE INTEREST OF THE MOTOR LIFE THAT TEMPERATURE RISE LIMIT SHOULD
BE UPTO CLASS B ONLY.

IT IS ESTIMATED THAT FOR EVERY 10 DEG RISE IN TEMPERATURE MORE

THEN THE SPECIFIED LIMIT, THE LIFE OF MOTOR REDUCES BY 12 MONTHS.
AND SINCE A MOTOR IS REQUIRED TO SERVE FOR A LONGER TIME IT WILL
BE A GOOD PRACTICE TO HAVE MAX WINDING TEMPERATURE OF ONLY
120 DEG (BY RESISTANCE METHOD) (KEEPING 10 DEG C MARGIN FOR HOT
SPOT TEMPERATURE.

MOTORS/GENERATORS ARE AVAILABLE IN VARIOUS CLASS OF INSULATIONS

MOST COMMON REPUTED MAKE BEING IN CLASS B AND CLASS F
(TRACTION MOTORS ARE ALSO AVAILABLE WITH CLASS H INSULATION SYSTEM.)
LEAVING A MARGIN FOR THE HOT SPOT TEMPERATURE, THE ALLOWED
TEMPERATURE RISE LIMITS FOR CLASS B AND F INSULATION AS PER VARIOUS
STANDARDS ARE AS FLLOWS:-
CLASS OF INSULATION………………………………………..….B……………………….F
ALLOWED TEMP RISE(OVER 40 DEG C AMB)………..80 DEG C…………….105 DEG C
BOTH MEASURED BY RESISTANCE MEASUREMENT OF WINDING IN HOT CONDITION

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 15

MACHINES REQUIRED WITH TEMP CLASS T3 AND T4 NEED SPECIAL DESIGN

CONSIDERATIONS AND NEED TO BE REFERRED TO CONSULTANTS/DESIGNERS
OF MANUFACTURERS.

4. MOTOR STARTING CONDITIONS:-

IF NOT SPECIFIED, MOTOR MANUFACTURERS, QUOTE FOR [Link]

INDUCTION MOTORS SUIITABLE WITH STARTING CURRENT APPROX 600%
FULL LOAD CURRENT SUBJECT TO TOLERANCE (WHICH PERMITS STARTING
CURRENT UPTO 720% FLC). THUS DURING STARTING THE SYSTEM MAY BE
SUBJECTED TO SUBSTANTIAL VOLTAGE DIP (SINCE WHEN AN INDUCTION
MOTOR IS STARTED WITH DIRECT ON LINE STARTING, DUE TO POOR
STARTING POWER FACTOR WHICH COULD BE OF THE ORDER OF 0.2 TO 0.3,
THERE IS SUBSTANTIAL VOLTAGE DIP, AND THIS MAY RESULT TRIPPING OF
THE BREKAER IF DUE CARE IS NOT TAKEN.

NOW A DAYS SOFT STARTERS ARE AVAILABLE WHICH PROVIDE INITIAL

RESISTANCE TO THE HIGH STARTING CURRENT AND THUS ALLOW SMOOTH
STARTING OF THE MOTOR BY LIMITING INITIAL STARTING CURRENT.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 16

AS SUCH IN CASE OF ANY STARTING CURRENT LIMITATION, IT SHOULD BE

INDICATED AT THE TENDER STAGE ITSELF AS IT HAS BEARING ON DESIGN
AND FRAME SELECTION OF THE MOTOR. IF THIS CONDITIONIS INDICATED
AT THE TENDER STAGE, THE TENDERER SHALL BE ABLE TO SELECT PROPER
FRAME FOR THE INDENTED RATING THUS AVOIDING PROBLEM
AT COMMISSIONING/EXECUTION STAGE.

IN CASE OF HIGH STARTING TORQUE REQUIREMENT, THE SAME SHOULD BE

INDICATED AT THE TENDER STAGE. FOR A HIGH STRATING TORQUE
REQUIREMNT CONDITION, THE TENDERER MAY HAVE TO SELECT A DOUBLE
CAGE INDUCTION MOTOR HAVING 2 CAGE WINDINGS ON THE ROTOR.

5. EFFECT OF AMBIENT AND ALTITUDE:-

IN TROPICAL CLIMATES LIKE IN INDIA/AND ASIAN REGION AMBIENTS MAY

VARY FROM 10 TO 50 DEG C WITH VARIED HUMIDITY.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 17

HOWEVER IN EUROPE AND AMERICA WHERE THERE ARE EXTREME COLD

CLIMATES WHICH MAY HAVE AMBIENTS VARYING FROM –35 DEG C TO 20 DEG C
WITH HUMIDITY ALSO VARYING UPTO 95% SUCH CONDITIONS ARE
ENTIRELY DIFFERENT FROM COUNTRIES LIKE INDIA/AND ASEAN COUNTRIES
AND THEREFORE AMBIENT, HUMIDITY, ALTITUDE AND SUCH CONDITIONS
SHOULD CLEARLY BE SPECIFIED BY THE BUYER AT THE TENDER STAGE.

IN ANY CASE , HOWEVER BUYER IS REQUIRED TO SPECIFY ONLY THE

ENVIRONMENTAL CONDITIONS AND IT IS OBLIGATORY ON THE PART OF
TENDERER FOR SELECTION AND DESIGN OF MOTORS/GENERATORS
AFTER IMPLEMENTING NECESSARY CORRECTIONS TO THIS EFFECT
BEFORE SUBMITTING THE QUOTATIONS.

SPECIAL REQUIREMENTS

ALL SPECIAL REQUIREMENTS, SPECIAL ACCESSORIES, INSTRUMENTATIONS

LIKE WINDING RTDS, BEARING RTDS, DIAL THERMAMETERS, HOT AND
COLD AIR RTDS/DIAL THERMOMETERS, FOUNDATION BOLTS
REQUIREMENTS OF TERMINAL BOXES, PROVISION FOR MOUNTING VIBRATION
PROBES, TACHO AND SIMILAR OTHER REQUIREMENT IF INDICATED AT TENDER
STAGE WILL BE HELP FUL TO BUYER TO GET A CORRECT OFFER AND
PRICE COMPARISION BRINGING ALL THE TENDERERS AT THE SAME FRAME/LEVEL.

8. EFFECT OF ATMOSPHERIC CONDITIONS:-

MOTOR MAY HAVE TO PERFORM IN VARIETY OF ATMOSPHERIC

CONDITIONS DEPENDING UPON GEOGRAPHICAL CONDITIONS,
TYPE OF PLANT, REGION, AND SEASON IN A YEAR.

CLEAN AND DUST FREE ATMOSPHERE IS EXCELLENT BUT THIS MAY BE

AVAILABLE IN A CLEAN POWER HOUSE OR IN A CLOSED DOOR WORKSHOP,
OR A VERY CLEAR DRY/DUST FREE REGION. SUCH ATMOSPHERE IS
SELDOMNLY AVAILABLE.

ATMOSPHERE EITHER WILL BE HUMID/CONTAMINATED OPEN AIR

SUSCEPTABLE TO RAINS/WINDS ETC OR TOO DUSTY(LIKE IN A CEMENT
PLANT) OF HAVING COAL PARTICLES(IN A COAL WASHERY/THERMAL POWER
STATION OR COLLIARY ETC) OR CHEMICAL PLANT AND SIMILAR
ATMOSPHERIC CONDITIONS, DEPENDING UPON THE DEGREE THE
PROTECTION TO ENCLOSURE RANGING FROM IP44 TO IP 55 IS REQUIRED
TO BE SELECTED AND SPECIFIED BY THE INDENTOR.

FOR SPECIAL CONDITIONS HAVING HAZARDOUS ATMOSPHERIC CONDITIONS

LIKE IN REFINERY/CHEMICAL/HEAVY HYDROGEN PROJECT/HEAVY
WATER PROJECT/GAS PLANT ETC) INVOLVE SPECIAL CLASS OF PROTECTION
AND WILL NEED MOTORS WITH ENCLOSURES WITH PRESSURISATION UNITS

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 18

OF FLAME PROOF MOTORS. THESE TYPES HAVE DIFFERENT IMPLICATIONS

AND THEREFORE CAREFUL SELECTION OF PROPER ENCLOSURE IS OF UTMOST
IMPORTANCE. SUCH ATMOSPHERES ARE LIKELY TO BE SUSTABLE TO
CATCHING FIRES AT HIGHER TEMPERATURES. AND THEREFORE THE BUYER
IS REQUIRED TO SPECIFY THE TEMPERATURE CLASS WHILE
INDICATING REQUIREMENT.
SUCH ATMOSPHERES ARE NORMALLY SPECIFIED AS GROUP C OR D OR E AND
ZONE 1, 2 OR 3 . FOR ATMOSPHERES SUSCEPTABLE TO EXTREME FIRE
CATCHING CONDITIONS INVARIABLY FLAME PROOF SPECIAL MOTORS ARE
TO BE USED.

THE INDIAN STANDARD 13408 INDICATES VARIOUS TEMPERATURE CLASSES

WHICH INDICATE LIMITATIONS FOR MAX TEMPERATURE FOR ANY SURFACE
OF THE MOTOR THESE ARE SPECIFIED AT TEMP CLASS T1, T2 , T3,T4, T5 AND T6
THE THEME IN THIS IS THAT THE SURFACE TEMPERATURE SHOULD IN
NO CASE EXCEED THE LIMITS SPECIFIED IN ABOVE CLASSES SO AS TO
PREVENT CHANCES OF FIRE BY INFLAMABLE GASES PRESENT IN THE VICINITY
OF THE MOTOR
FOR EACH TEMP CLASS VARIOUS LIMITS GIVEN ARE AS FOLLOWS:-
TEMP CLASS T1………………………..450 DEG C
TEMP CLASS T2……………………….300 DEG C
TEMP CLASS T4……………………….150 DEG C
TEMP CLASS T5……………………….120 DEG C
AND TEMP CLASS T6……………..….. 85 DEG C

9. NOISE AND VIBRATION OF MOTORS

VARIOUS STANDARDS ARE AVAILABLE WHICH IDENTIFY NOISE AND

VIBRATIONS VALUES FOR MOTORS OF DIFFERENT RATINGS AT DIFFERENT
SPEEDS. HOWEVER FOLLOWING ARE WORTH CONSIDERING WHILE INDENTING
AN EQUIPMENT:-

A) NOISE:- NOW A DAYS NOISE POLLUTION HAS GAINED IMPORTANCE AND

GENERALLY NOISE LEVELS OF THE ORDER OF 85 DBA OR LESS ARE BEING ACCEPTED
BY WESTERN COUNTRIES PARTICULARLY USA/CANADA.

FOR SPECIAL APPLICATIONS LIKE FRIGATES/SUBMARINES NOIZSE LEVELS EVEN

LESS THEN 70 dBA ARE REQUIRED FOR MG SETS/ALTERNATORS.

WHILE FOR 6P AND 4P MOTORS NOISE LEVELS ARE POSSIBLE TO ACHIEVE

IN THESE LIMITS. FOR 2 POLE MOTORS DUE TO HIGH AIR TURBULANCE OF
AIR AND HIGH PERIPHERIAL SPEEDS NOISE LEVELS OF THESE ORDER
ARE DIFFICULT TO ACHIEVE. SOME REPUTED MANUFACTURES DEPLOY
NOISE REDUCERS AT NDE SIDE OF THE MOTORS TO REDUCE NOISE LEVELS.

IN WESTERN COUNTRIES PARTICULARLY IN USA FOR REDUCTION IN NOISE LEVELS,

ALTERNATORS AND LARGE MOTORS ARE HOUSED IN DOUBLE LAYER BOXES AND

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 19

INTER LAYER IS PROVIDED WITH NOISE ABSORBERS..

PRIMARILY IT IS VENTILATION AND AIR CIRCULATION CIRCUIT WHICH IS
RESPONSIBLE AND THERE FORE NEEDS TO BE CONSIDERED BY THE VENDOR
WHILE QUOTING A MOTOR./ELECTRICAL EQUIPMENT.

B) VIBRATION:-

IN TEST FIELD /TEST BED IT IS A COMMON PRACTICE TO MEASURE VIBRATION

BOTH IN VELOCITY MODE AND DISPLACEMENT MODE.
I.E. VELOCITY …………..IN MM/SEC
DISPLACEMENT….…IN MICRONS
THESE MEASUREMENTS ARE DONE AT PLACES LIKE PEDESTAL/BEARING
AT MOTOR BASE.(ONLY FOR REFERENCE PURPOSE) AT DRIVE END AND
NON DRIVE END OF THE MOTOR.

VIBRATIONS ARE MEASURED AT VERTICAL, HORIZONTAL AND AXIAL

DIRECTIONS.
VERTICAL VALUES ….INDICATES HEALTHYNESS / CORRECTNESS OF
MOUNTING PADS/FOUNDATION
AXIAL VALUES …………INDICATES ABOUT PROPER ALIGNMENT
OF EQUIPMENT WRT SLAVE(DRIVING UNIT)
OR WITH RESPECT TO MACHINE ITSELF
HORIZONTAL VALUES ..INDICATES WHETHER ROTOR OF THE MACHINE
HAS BEEN PROPERLY BALANCED OR NOT

VIBRATION VALUES BOTH IN DISPLACEMENT AND VELOCITY MODE

IN ALL I.E. VERTICAL, HORIZONTAL AND AXIAL AXIS ARE [Link]
VELOCITY MODE IS MORE IMPORTANT FROM POINT OF VIOEW OF FOUNDATION
DESIGN AS IN FOUNDATION DESIGN CALCULATIONS MM/SEC(VELOCITY
MEASUREMENT) ARE CONSIDERED FOR ANALYSING DAMPED VIBRATIONS AND
NATURAL FREQUENCY OF VIBRATION OF THE WHOLE SYSTEM WHEN EQUIPMENT
AND SYSTEMARE CONSIDERED COMBINED TOGETHER(REF FOUNDATION DESIGN
HAND BOOK BY VIDYANATHAN AND SOMAYUJULU)

RELEVENT IS/IEC STANDARDS GIVES GUIDE LINES FOR LIMITING VALUES

FOR VARIOUS SPEED/RATINGS.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 20

10. MOTOR BEARINGS :-

THIS IS A COMPONENT WHICH ALLOWS ROTOR OF THE MOTOR TO REST

ON THE STATOR THROUGH END SHIELD/BEARING PEDESTALS AND WHILE
RUNNING FACILIATES FREE ROTATION OF ROTOR FOR DELIVERY OF
REQUIRED TORQUE THROUGH SHAFT EXTENSION

A MOTOR OR A GENERATOR CAN HAVE TWO TYPES OF BEARING SUPPORTS:-

A) BALL AND ROLLER BEARINGS WHICH ARE HOUSED IN BEARING INNER RACE
AND OUTER RACE. THE BEARING OUTER RACE IS FITTED IN BEARING HOUSING
WHICH IF CLAMPED TO THE STATOR THROUGH END SHIELDS. WHILE INNER RACE IS
SHRINKED ON THE ROTOR SHAFT. IT IS THIS INNER RACE WHICH ROTATES WITH THE
SHAFT. THE BALL/ROLLER BEARING FACILIATE EASY/FRICTION FREE ROTATION
THROUGH CONTINUOUS CONTACT BETWEEN INNER RACE AND OUTER RACE.

A COMBINATION OF BALL AND ROLLER BEARING IS FITTED ON DRIVING END SIDE OF

THE SHAFT(OR MOTOR) BECAUSE THE SHAFT EXTENSION IS SUBJECTED TO THE
LOAD. THE NON DRIVING END SIDE IS FITTED WITH BALL BEARINGS.

THESE BEARINGS ARE CALLED ANTI FRICTION GREASE LUBRICATED BEARINGS.

SUCH BEARINGS HAVE LIMITED LIFE IN TERMS OF HOURS OF RUN. BEARING LIFE IS
GENERALLY SPECIFIED BY THE SUPPLIER OF MOTORS/GENERATORS AND SHOULD BE
ASKED BY THE BUYER WHILE INDENTING FOR THE EQUIPMENT.

IN GENERAL BALL BEARINGS CAN TAKE AXIAL THRUST(BUT THERE IS NO OR VERY

LITTLE AXIAL PLAY) WHILE ROLLER BEARINGS CAN HAVE AXIAL PLAY(AND THERE
FORE AXIAL THRUST IS NOT ALLOWED ON MOTORS PROVIDED WITH ROLLER
BEARINGS) THIS IS THE REASON WHY DRIVE END SIDE BEARING HAS COMBINATION
OF BALL AND ROLLER BEARING SO AS TO TAKE SOME AXIAL THRUST DURING
LOADING

B) OTHER TYPE IS END SHIELD OR PEDESTAL MOUNTED SLEEVE BEARINGS

THESE CONSIST OF A ROUND BUSH HAVING HIGH PRECISION BABBITING MATERIAL

DEPOSITED ON INSIDE OF THE SLEEVE BY HIGH SPEED CENTRIFUGAL PROCESS. AND
LATER FINE MACHINING TO ACHIEVE REQUIRED INNER DIA OF THE SLEEVE. THE
BABBITING MATERIAL HAS PORSITY TO RETAIN LUBRICATING OIL. SLEEVE
BEARINGS WORK ON THE PRINCIPLE THAT THE LUBRICATING OIL (GENERALLY ISO
VG 46 OR 48 OR 62) WHEN INTRODUCED INTO THE SLEEVE AT A PRESSURE (MAY BE 0.2
TO 0.5 BAR) WILL FORM A THIN FILM BETWEEN THE BABBIT MATERIAL OF THE BUSH
AND THE SHAFT. THE FILM THICKNESS IS SUCH THAT IT CAN SUSTAIN THE LOAD OF
THE ROTATING SHAFT(INCLUDING ROTOR). THE OIL IN THE SLEEVE BEARING IS
FORCED THROUGH FOL SYSTEM WHICH IS SUPPLIED ALONGWITH

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 21

THE MOTOR/GENERATOR .

THESE TYPE OF BEARING ARRANGEMENT THEORITICALLY HAS UNLIMITED

LIFE AS LONG AS OIL FLOW RATE AND PRESSURES ARE MAINTAINED.

HOWEVER DUE TO PROLONGED OPERATION, BABBIT MATERIAL MAY WORN OUT

AND THE BEARING SLEEVES MAY HAVE TO BE REPLACED IF VIBRATIONS ARE
GOING BEYOND PERMISSIBLE LIMITS. BEFORE STARTING THE MOTOR
OR GENERATOR WITH SLEEVE BEARING ARRANGEMENT, IT SHOULD BE
ENSURED THAT REQUIRED QUANTITY OF OIL FLOW AND PRESURE IS MAINTAINED.

THE CAUSE OF WEARING OUT SUCH SLEEVE BEARINGS IS PRIMARILY DUE TO

CANTAMINATED OIL/LESS VISCOUS OIL OR TOO MANY STARTS AND STOPS. WHEN
THE MOTOR IS AT REST, THE SHAFT RESTS ON THE BABBIT MATERIAL. THOUGH OIL
QUANTITY AND PRESSURE IS MAINTAINED, THE PORTION AT WHICH SHAFT IS AT REST
ON THE SLEEVE, THER IS VERY LITTLE OIL FILM OR NO FILM. IT IS ONLY AT T=DELTA
T THAT OIL RUSHES IN THIS PORTION INITIATING THE FILM. LIKE THIS THERE
COULD BE SOME EROSION OF BABIT MATERIAL. SIMILARLY DUE TO CONTAMINATED
OIL, LOW VISCOSITY THERE IS IN SUFFICIENT FILM FORMATION OF SKRETCH MARKS
RESULTING EROSION OF BABIT MATERIAL RESULTING WEARING OUT OF SLEEVES
NEEDING REPLACEMENTS.

IN GENERAL FOR 2 P MOTORS AND MACHINES REQUIRING TO TRANSMIT LARGE

TORQUES IT IS PREFERABLE TO HAVE MOTORS WITH SLEEVE BEARINGS AS THEIR
MAINTENANCE AND OPERATION IS EASY.

SLEEVE BEARINGS CAN NOT TAKE ANY AXIAL THRUST AND WILL HAVE AXIAL FLOAT
AS SHAFT IS FREE FOR AXIAL MOVEMENT(WITHIN BUSH LIMITS). THEREFORE IN
SUCH MACHINES, MAGNETIC IS VERY IMPORTANT TO PREVENT EXCESSIVE AXIAL
FLOAT. MANY TIMES DESIGNERS RECOMMEND TO CONTROL AXIAL FLOAT BY
LIMITING FLOAT IN THE COUPLING. TYPICALLY FOR PEDESTAL
MOUNTED ALTERNATORS MAX ALLOWED AXIAL FLOAT IS +/-- 1.5 MM TO
BE CONTROLLED IN THE COUPLINGS.

C) FOR VERTICAL MOTORS DRIVE END SIDE(BOTTOM) HAS ROLLER BEARINGS AND
NON DRIVE END SIDE HAS ANGULAR CONTACT ROLLER BEARINGS.
IT IS RECOMMENDED THAT PUMP THRUST SHOULD NOT BE TRANSFERRED ON THE
MOTOR BEARING SINCE AT DRIVE END SIDE THE MOTORS ARE PROVIDED WITH
ROLLER BEARINGS. GENERALLY PUMPS SHOULD BE SO SELECTED THAT THE
BEARINGS OF THE PUMP ARE ABLE TO TAKE ANY AXIAL THRUST GENERATED DURING
LOADING OF THE PUMP.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 22

12 PERFORMANCE EVALUATION(AT WORKS):-

ALL THE MANUFACTURERS HAVE SEPARATE TEST BED FACILITY WHERE

MOTORS CAN BE SUBJECTED TO FIELD TRIALS.

A1 MOTORS OF EACH DESIGN ARE SUBJECTED TO TYPE TESTS(INCLUDING ROUTINE

TESTS)
LIST OF TESTS ARE INDICATED IN VARIOUS SATANDARDS FOR SUCH TESTS.
FOR WHICH VARIOUS STANDARDS ARE AVAILABLE. SINCE DETAILS OF TESTS
ARE ELABORATED IN THE RELEVENT STANDARTDS, THEY ARE NOT LISTED HERE
AND FOCUS ON KEY ISSUES.

A2 MOTORS OF REPEAT DESIGN ARE SUBJECTED ONLY FOR ROUTINE TESTS.

A3 IN CASE OF FLAME PROOF MOTORS , SINCE EACH MOTOR IS LIKELY TO BE

SUBJECTED TO HAZARDOUS ATMOSPHERE, EACH MOTOR IS REQUIRED TO BE
TESTED AT CMRI/DHANBAD FOR ASCERTAINING ITS CORRECTNESS OF ENCLOSURE
FR FLAME PROOF FAIL SAFE OPERATIONS. IT MAY BE NOTED THAT AT
CMRI DHANBAD ONLY PROTECTION TO ENCLOSURE IS ASCERTAINED AND BALANCE
TESTS ARE TO BE CARRIED OUT AT MANUFACTURER’S WORKS.

A4 TYPE TESTS INCLUDE A SERIES OF TESTS INCLUDING HEAT RUN TEST FOR
EVALUATION OF TEMPERATURE RISE FOR MOTOR WINDING AND OTHER
PARTS. BESIDE THIS MANUFACTURER ALSO USES THIS DATA OF TESTS FOR
EVALUATION OF EFFICIENCY.

METHODS OF PERFORMANCE EVALUATION DURING TEST BED FIELD TRIALS:-

A) CALCULATION OF TEMP RISE AND LOSSES:-

THERE IS NO DIRECT METHOD OF MEASUREMENT OF OUTPUT OF THE MOTOR.

THOUGH IN LABORATORIES STRAIN GAUGES ARE FIXED ON THE SHAFT AND
TORQUE CAN BE MEASURED TO ASCERTAIN OUTPUT BEING DELIVERED BY THE
MOTOR DURING VARIOUS LOAD, THIS CAN ONLY BE A LOABORATOR MODEL AND
FOR A MANUFACTURER, NEEDING TO PRODUCE 400 TO 600 MOTORS OF DIFFERENT
DESIGNS( ROUGHLY 150 TO 200 ON AN AVERAGE) IT IS NEITHER POSSIBLE NOR
PRACTICAL TO TYPE TEST MOTORS ON LINES OF LABORATORY MODELS.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 23

THEREFORE, A MUCH SIMPLER AND ASSERTIVE METHOD IS TO ASSESS INPUT POWER

SUPPLY AND FEED TO THE MOTOR. THE METHOD INVOLVES :-

A) ASSESSMENT OF TEMP RISE AND FULL LOAD LOSSES.

1) ASSESSMENT OF INPUT POWER BY DIVIDING THE RATED OUT PUT RATING BY THE
GUARANTEED EFFICIENCY(OR THE DESIGNED EFFICIENCY)
2) MOTOR IS RUN AT ABOVE INPUT POWER SUPPLY AT RATED VOLTAGE AND
CURRENT DRAWN BY THE MOTOR IS MEASURED. THE CURRENT VALUE SHOULD BE
NEAR TO THE DESIGNED FULL LOAD AMPS. IF THE MOTOR IS DRAWING MORE
CURRENT(WITHIN PERMISSIBLE VARIATION) IT SHOWS THAT THE MOTOR MAY
HAVE POWER FACTOR LOWER THEN THE DESIGNED OR THE MOTOR MAY HAVE
MORE LOSSES. IN SUCH CASES DESIGNER MAY HAVE TO BE REFERRED THE CASE.
3) INPUT KW, KVA, POWER FACTOR, SPEED, BEARING TEMP, STATOR FRAME
TEMPERATURE AND OTHER PARAMETERS ARE REQUIRED TO BE MEASURED WITH
TIME INTERVAL TILL THE MOTOR HAS REACHED POSITION OF THERMAL
EQUILIBRIUM(I.E TEMP RISE HAS STABILISED)
4) MOTOR IS PUT FOR SHUT DOWN AND HOT WINDING TEMPERATURE IS MEASURED.
GENERALLY IT TAKES SOME TIME FOR THE MOTOR TO COME TO REST
AFTERWHICH ONLY HOT WINDING RESISTANCE TO BE MEASURED WITH THE
BRIDGE (THERE ARE SEPARATE STANDARDS FOR METHOD OF MEASUREMENT AND
CORRECTION FACTORS TO BE IMPLIED FOR ARRIVING HOT WINDING
TEMPERATURE AT THE INSTANT OF SHUT DOWN). THIS WILL CONFIRMATION OF
SUITABILITY OF MOTOR FOR THE INDENTED TEMPERATURE RISE.

B) ASSESSMENT OF EFFICIENCY:-

FOR ASSESSMENT OF EFFICIENCY WE NEED NO LOAD LOSSES(COMPRISING IRON LOSS,

FRICTION AND WINDAGE LOSS ) AND FULL LOAD LOSSES, STRAY LOAD LOSSES.

1) NO LOAD LOSS ASSESSMENT:-

@ MOTOR IS RUN AT NO LOAD AT VARIOUS VOLTAGES(GENERALLY FROM 120% RATED
VOLTAGE TO 25% RATED VOLTAGE) AND INPUT KW, AND CURRENT IS NOTED. A GRAPH
IS DRAWN BETWEEN INPUT KW AND VOLTAGE. THE GRAPH IS INTERPOLATED BELOW
25% RATED VOLTAGE SUCH THAT IT INTERSECTES Y –AXIS. THE PORTION XX SHOWN
WILL BE FRICTION AND WINDAGE LOSS. AND BALANCE WILL BE IRON LOSS+
NO LOAD COPPER LOSS.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 24

2) FULL LOAD LOSS IS KNOWN FROM TEMPERATURE RISE TEST CARRIED

AS PER PARA A ABOVE
3) TOTAL LOSSES = NO LOAD LOSS+ FULL LOAD LOSS+ STRAY LOAD LOSS
4) EFFICIENCY= (INPUT-TOTAL LOSSES)/INPUTX100 = % EFFY.

4 MEASUREMENT OF LOCKED ROTOR TORQUE

FOR CARRYING OUT THIS TEST, THE MOTOR IS CLAMPED WITH THE BED FIRMELY AND
SHAFT IS ALSO PROPERLY LOCKED SO AS TO PREVENT ITS ROTATION.
CURRENT IS SUPPLIED AT 100%, 150% AND 200% OF RATED CURRENT AND VOLTAGE IS
MEASURED AT EACH CURRENT VALUE
INPUT POWER IS ALSO MEASURED.
FROM ABOVE DATA, AS PER JEC 37 LOCKED ROTOR TORQUE AND CURRENTS ARE
EVALUATED.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 25

5 ASSESSMENT OF OTHER PARAMETERS:-

OTHER PARAMETERS IMPORTANT FROM PERFORMANCE POINT OF VIEW ARE:-

VIBRATION … . LIMITES SHALL BE IN LINE WITH GUIDE LINES GIVEN

IN RELEVENT STANDARDS FOR RATINGS, SPEEDS AND
TYPE OF MOUNTING.

NOISE ………… . NOISE LEVELS ALSO VARY FOR DIFFERENT MACHINES,

ITS VALUES WILL DEPEND ON SIZE, TYPE, SPEED AND OTHER
PARAMETERS FOR WHICH RELEVENT STANDARDS CAN BE
REFERRED.

SHAFT ……… . .IN ANY MOTOR THEORITICALLY SHAFT VOLTAGE SHOULD

VOLTAGE BE ZERO. HOWEVER IT IS NOT PRACTICAL AND THERE WILL

BE SOME RESIDUAL VOLTAGE . HOWEVER EFFORTS SHOULD
BE TO KEEP IT MINIMAL. AND TAKE PREVENTATIVE BY
INSULATING ONE SIDE BEARING TO AVOID ANY CIRCULATING
CURRENT (WHICH WILL RESULT IN ITCHING OF BEARING)

IR, PI, HV AND TAN DELTA TESTS:-

THOUGH IN ALL STAGES OF MANUFACTURE, STATORS WOUND

ROTORS ARE SUBJECTED TO STAGE INSPECTION, WHICH
INCLUDE INTER TURN TEST AND HIGH VOLTAGE TEST,
IT IS CUSTOMARY TO CONDUCT THESE TESTS AFTER ALL THE
PERFORMANCE TRIALS ARE COMPLETED.

1) BEFORE CONDUCTING H.V. TEST IT IS ESSENTIAL TO CARRY OUT IR TEST FOR

VARIOUS WINDINGS. AND IF IR VALUE IS LOW IT IS NECESSARY TO INVEASTIGATE
CAUSE OF LOW IR VALUE.

IR VALUE TEST IS TO BE DONE WITH SUITABLE MEGGERING INSTRUMENTS WHICH

ARE AVAILABLE IN VARIOUS VOLTAGES OF 500 VOLTS TO 5KV. DEPENDING UPON
THE VOLTAGE CLASS OF MACHINE (LT, 3.3KV, 6.6KV, OR 11 KV) TEST VOLTAGE FOR
MEGGERING SHOULD BE SELECTED.

2) PI VALUE TEST:

THIS IS POLARISATION INDEX TEST AND INVOLVES MEASUREMENT OF IR VALUE

BETWEEN 1 MINUTE AND 10 MINUTE INTERVAL THE UNDERLYING PRINCIPLE IS
THAT EACH WINDING WITH CONNECTING CABLES, TERMINAL BUSHING ETC IS A
SERIES OF HIGHE RESISTANCES AND CAPACITANCES. TYPICALLY IN ELECTRICAL
TERMS IT CAN BE SHOWN AS FOLLOWS:-

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 26

WHEN A VOLTAGE IS APPLIED, INITIALLY DUE TO CAPACITANCE IN THE CIRCUIT,

CHARGING CURRENT WILL FLOW THUS SHOWING LOW IR VALUE. AS THE TIME
PASSES THE CAPACITORS WILL GET CHARGED RESISTING THE FLOW OF CURRENT
SHO WING INCREASING RESISTANCE VALUE . IN A DRY ATMOSPHERE,
RECOMMENDED VALUES OF RATIO OF IR BETWEEN 10 MINUTES AND 1 MINUTE ARE
RECOMMENDED TO BE 2.0 AS PER IEEE 43-1974. THIS CAN BE CONSIDERED
AS GENERAL GUIDE LINES ONLY.

IT MAY BE NOTED THAT EVEN SURROUNDING VOLUME OF AIR IS ALSO GETTING

ENERGISED. AND IF DUST , MOISTURE ARE AVAILABLE IN THE VICINITY OF CABLES
OR BUSHING THEY MAY GIVE LOW RESISTANCE PATH FOR DISCHARGING
CURRENT RESULTING NO SUBSTANTIAL IMPROVEMENT IN THE RATIO.
PRACTICAL FIELD TESTS HAVE SHOWN THAT GLASS BRADED SILICON CABLES
USED FOR CONNECTING STATOR LEADS TO TERMINAL BUSHINGS , DUE TO GLASS
BRADING USED TO GIVE NO SUBSTANTIAL IMPROVEMENT IN IR VALUE, BUT WHEN
GLASS BRADING AT THE CABLE L UGS FOR APPROX 100 TO 150 MM WAS
REMOVED, THE IR VALUE SHOWED IMPROVEMENTS.

MORE OVER, FOR PI VALUE THERE IS NO WRITTEN STANDARD AND VARIOUS WRITE -
-UPS HAVE NOT BEEN UPDATED TAKING INTO ACCOUNT THE DEVELOPMENTS
TAKEN IN THE FIELD OF VARNISHES/INSULATIONS NOW BEING EMPLOYED FOR
WINDING AND OTHER LIVE

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 27

PARTS OF THE MOTORS/EQUIPMENT. THEREFORE HIGH INITIAL IR

VALUES RECORDED AT 1 MIN TEST IT SELF MAY BE VERY HIGH.

AS SUCH PARTICULARLY DURING RAINY SEASON WHEN ATMOSPHERE IS HUMID, IN

CASE RATIO OF IR VALUE BETWEEN 10 MIN TO 1 MIN IS LOW, BUT IF INITIAL IR
VALUE(1 MIN VALUE) IS VERY HIGH , AFTER CONSULTING DESIGNERS/EXPERTS IT
CAN BE CONSIDERED TO GO FOR HV TESTS .

SIGNIFICANCE OF TAN DELTA TEST:-

THIS TEST IS PERFORMED TO ASCERTAIN THE DIELECTRIC STRENGTH OF

INSULATION. THIS TESTS IF GENERALLY PERFORMED FOR MACHINES OF 11 KV OF 6.
6KV. AND IS A MEASURE O F THE LONGIVITY OF THE INSULATION
DURING PROLONGED USE.

THOUGH THERE IS NO STANDARD LAID DOWN FOR THIS TEST THE RECORDS OF
THIS TEST CAN BE KEPT FOR THE REFERENCE PURPOSE. DURING SERVICE OF
OPERATION (COULD BE 2 YEARS OR 3 YEARS) TAN DELTA MEASUREMENTS AT SITE
SHOULD NOT SHOW LARGE DETORIATION. IF RECORDS SHOW DETORIATION THEN
THIS WILL M EAN THAT WINDING INSULATION IS TO BE RESTRENGTHENED TO
IMPROVE LIFE OF MOTOR . THIS TEST IS USEFUL FOR THE PURPOSE OF RESIDUAL
LIFE ACCEPTANCY STUDY OF M OTORS. ENERGY AUDITORS MAY FIND THE TEST
USEFUL DURING RLA STUDY

THE TAND DELTA VALUE LIMITS MAY VARY FROM MANUFACTURER TO

MANUFACTURER HOWEVER REPUTED MANUFACTURERS GENE RALLY HAVE BEEN
FOUND TO CONSIDER TAN DELTA VALUE RANGING FROM 0.02 TO 0.035

THE TEST INVOLVES SUPPLY OF PART VOLTAGES RANGING FROM 20% TO 110% OF
RATED VOLTAGE ACROSS EACH PAHSE OF THE STATOR WINDING FOR SHORT
DURATION AND RECORDING TAN DELTA VALUES AND CORRESPONDING
CAPACITANCE VALUES AT EACH VOLTAGE. TAN DELTA VALUES SHOULD NO T
EXCEED THE DEPARTMENT SPECIFIED V ALUES LAID DOWN BY
THE MANUFACTURER.

13 PERFORMANCE ASSESSMENT OF MOTORS IN OPERATION:-

SINCE WORLD OVER FOCUS IS ON ENERGY CONSERVATION AND SAVING ON
ENERGY,PERFORMANCE ASSESSMENT OF MOTORS DURING OPERATIONS
PARTICULARLY WHEN THEY ARE RUNNING AT PART LOADS OR HAVE SERVED FOR
LONG PERIOD HAS GAINED IMPORTANCE:

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 28
PERFORAMNCE ASSESSMENT OF SERVICED OR REWOUND MOTORS IS IMPORTANT
SINCE DURING SERVICE/REWINDING THERE COULD BE MODIFICATIONS OR CHANGES.
EVEN IF CHANGES ARE NOT CARRIED, IT IS IMPORTANT TO KNOW WHETHER ALL THE
REQUIRE D OPERATION ARE CARRIED OUT PROPERLY FOR ANY RISK OF FAILURE OR
POOR PERFORMANCE.

IT MAY BE NOTED THAT AT SITE, ALL THE NECESSARY INSTRUMENTATION,

EQUIPMENT(WHICH ARE GENERALLY AVAILABLE AT SUPLIER’S WORK) MAY NOT BE
AVAILABLE AND THEREFORE ASSESSMENT MAY BE REQUIRED TO BECARRIED OUT
FROM THE AVAILABLE OR BORROWED INSTRUMENTS.

A) ASSESSMENT BY INPUT DATA:-

ASSUMING THE MOTOR IS CONNECTED TO THE LOAD AND IN OPERATION, ME
ASURE THE IN PUT POWER BY PORTABLE POWER ANALYSER, OR 2/3 PHASE POWER
METER.

RATED POWER AND EFFICIENCY CAN BE NOTED FROM MOTOR DATA SHEET OR
RATING PLATE . BASED ON T HIS DATA RATED INPUT CAN BE CALCULATED AS
FOLLOWS:-
R ATED INPUT POWER = RATED OUTPUT/EFFICIENCY

T HE PERCENTAGE LOADING = ACTUAL INPUT POWER/RATED INPUT POWER

B) ASSESSMENT BY INPUT CURRENT

SOME TIMES POWER ANALYSER MAY NOT BE AVAILABLE AT SITE. THEN MOTOR
LOADING CAN BE FOUND OUT BY MEASURING INPUT CURRENT AND DIVIDING SAME
BY RATED CURRENT.
HOWEVER THIS METHOD IS USEFUL FOR LOADING UPTO 75% OF FULL LOAD
CURRENT SINCE BELOW THIS LOADING POWER FACTOR OF THE MOTOR MAY GO
SUBSTANTIALLY DOWN AND RESULTS MAY NOT BE ACCURATE.

C) ASSESSMENT BY SPEED:-
SOME TIMES EVEN CURRENT MEASUREMENT IS NOT POSS IBLE, THEN % LOADING
CAN BE EVALUATED BASED ON ACTUAL MOTOR SPEE D.
% = (SYN SPEED-MEASURED SPEED LOADING
(SYN SPEED-RATED SPEED) X (VR/V)SQ
WHERE VR = RATED VOLTAGE, V= ACTUAL VOLTAGE

ACCURACY OF THIS METHOD HOWEVER IS LIMITED AS THE SLIPS

INDICATED ON THE RATING PLATE MAY BE ROUNDED OFF TO NEAREST
MULTIPLE OF 5. FOR CORRECTNESS ACTUAL SUPPLIER TEST DATA MAY BE
REFERRED.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 29

14 MOTORS AND ENERGY CONSERVATION:-

MOST OF THE INDUSTRIES USE LT OR HT MOTORS FOR CONVERTING ELECTRICAL

POWER INTO USEFUL MECHANICAL WORK AND ALL THE MOTORS WORK WITH
POWER FACTORS RANGING BETWEEN 0.86 TO 0.75. AND THEREFORE
FULL LOADING OF MOTORS IS VERY IMPORTANT FROM ENERGY CONSERVATION
POINT OF VIEW.

UNDERLOADING WHICH COULD BE RESULT OF MARGINS IN DESIGNS, SAFETY

FACTOR CONSIDERED BY THE USER/MECHANICAL EQUIPMENT SUPPLIER ETC AND
MAY RESULTS IN POOR P OWER FACTOR AND LOW EFFICIENCY.

IN GENERAL, IF MOTORS ARE OPERATING WITH LOADING ABOVE 60% IT MAY NOT
BE NECESSARY TO CHANGE THE MOTORS. HOWEVER FOR APPLICATIONS LIKE
PUMPS WHERE WITH SUITABLE PIPING MODIFICATIONS, CLUBBING OF PUMPS IS
POSSIBLE, REDUCED FLOW RATES CAN BE ACHIEVED BY SHUTING DOWN SOME
PUMPS . SIMILAR IN CASE OF FANS IF REDUCED QUANTITY OF GAS OR AIR IS
REQUIRED IT IS PREFERABLE TO USE VVF CONTROL IN PLACE OF PARTIAL CLOSING
OF DAMPERS. IN CASE OF COMPRESSORS ALSO THE COM,PTRESSOR WHICH IS OF
LOWEST CAPACITY SHOUL BE ALLOWED TO GO FOR LOAD VARIATIONS. AND FEW
OF COMPRESSORS CAN BE SHUT DOWN BY SUITABLE ON OFF CONTROL SYSTEM.

CHANGES IN MOTORS ARE ATTRACTIVE WHERE EVER THERE IS WIDE DIFFERENCE

IN EXISTING MOTOR RATING AND REAL REQUIRED LOAD. IN GENERAL
REPLACEMENT SHOULD BE CONSIDERED AFTER ADOPTING ALL POSSIBLE MEASU
RES MENTIONED ABOVE AND OTHER MEANS OF COST EFFECTIVE ENERGY SAVING
MEASURES.

CONSERVATION OF ENERGY IN MOTORS: -

WORLD OVER POWER PLANTS OPERATE WITH EFFICIENCIES RANGING FROM 28 TO

35% WITH RESPECT TO SIZE, AGE AND UTILITY FACTOR. OUT OF TOTAL POWER
PRODUCED ONLY 50% IS GETTING CONVERTED INTO USEFUL OUT, REST GETTING
WASTED IN TRANSMISSION, DISTRIBUTION, PILFIRAGE AND OTHER INTERFACE
ELECTRICAL EQUIPMENT/CONTROLS.
OUT OF TOTAL POWER GENERATED (IN INDIAN CONTEST), 49% IS CONSUMED IN
INDUSTRY, 22 % IS CONSUMED IN TRANSPORT SECTOR, and 10% IS CON SUMED IN
RESIDENTIAL, 5 TO 10 % IN AGRICULTURE AND REMAINING IN MISC CONSUMPTIONS

THUS MAJOR JUNK OF ENERGY IS CONSUMED IN INDUSTRY AND TRANSPORT AND

AGRICULTURAL SECTOR. ENERGY CONSERVATION IN THESE AREAS CAN PLAY VITAL
ENERGY SAVING ROLE IF ENERGY IS PROPERLY USED.

CONSIDERING LIMITED EXHAUSTING NON RENEWABEL RESOURCES, IT WILL BE

PRUDENT TO OPTIMISE USE OF ENERGY FOR BENEFIT OF SOCIETY AT LARGE BY;

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 30

1) SELECTING MOTOR RATINGS NEARER TO DUTY POINT

USING RATING NEARER TO DUTY POINT RATING. AN OVER SIZED MOTOR

OPERATING AT PARTIAL LOADS WILL BE OPERATING AT POOR POWER FACTOR AND
EFFICIENCY RESULTING ENERGY LOSSES.

2) USING MOTORS WITH VARIABLE SPEED CONTROLS .

THESE REQUIRE DEPLOYING VARIABLE VOLTAGE VARIABLE FREQUENCY

CONTROL PANELS. THIS IS MORE USEFULE IN CAS E OF FANS/PUMPS WHICH AS A
SYSTEM F OLLOW AFFINITY LAW IN WHICH CASE
Q = Kx N
HEAD = K X (N) SQ
POWER = K (N)3 OR = Kx (Q)3
THUS TO REDUCE THE FLOW IF SPEED IS REDUCED BY 20% KW POWER
REQUIREMENT WILL REDUCE BY 40% THEREBY SAVING ON LOT OF ENERGY IN
MOTOR. OFFCOURSE PANEL EFFICEIENCY WILL HAVE TO BE TAKEN INTO
ACCOUNT.

HOWEVER PUMP SPPEDS CAN ONLY BE REDUCED TO SOME EXTENT. IT IS NOT

ADVISABLE TO REDUCE PUMP SPEED BEYOND 75% OF ITS FULL SPEED, AS THE
PUMPS MAY NOT GENERATE REQUIRED NET POSITIVE SUCTION HEAD REQUIRED TO
MAINTAIN REQUIRED FLOW RATE.

15 TRANSPORTATION OF MOTORS

PACKING AND TRANSPORTATION OF EQUIPMENT PLAYS A VITAL ROLE IN SAFE

RECEIPT OF TESTED AND FINISHED MOTOR OR GENERATOR TO ITS DISTINATION. A
NICELY TESTED EQUIPMENT REACHING SITE WITH DISTURBED ALIGNMENT WILL
ATTRACT REWORK, DELAYS AND COST OVER RUNS.

THE VITAL PARTS LIKE SHAFT EXTENSION WHICH WILL BE COUPLED TO THE
DRIVEN EQUIPMENT THROUGH COUPLING HAS TO BE DENT FREE FOR PROPER
FITTING OF COUPLING. SIMILARLY THE INSTRUMENTATION PART LIKE, DIAL
THERMAMETERS, BEARING TEMPERATURE DETECTORS, AND OTHER INSTRUMENTS
FITTED ON THE EQUIPMENT SHOULD BE PROPERLY SECURED AND PROTECTED
BEFORE CARRYING OUT P ACKING WORK.

FOR PROTECTION OF SHAFT - FOR SMALL AND MEDIUM MOTORS SHAFT

EXTENSION GUARDS ARE PROVIDED BY THE MANUFACTURERS.
WHERE EVER MOTORS ARE PROVIDED WITH SLEEVE BEARINGS , IT IS CUSTOMERY
TO PROVIDE LOCKING ARRANGEMENT FOR THE SHAFT TO PREVENT MOVEMENT OF
ROTOR DURING TRANSIT. THIS IS REQUIRED TO PREVENT ANY DAMAGE TO THE
SLEEVE BEARING PROVIDED IN THE GENERATOR/MOTOR. IN THIS CASE ALSO
PROPER PROTECTION TO THE SHAFT EXTENSION IS REQUIRED T O PREVENT ANY
DAMAGE DURING UNLOADING/OPENING O F PACKING BOX AND ERECTION .

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 31

PACKING OF EQUIPMENT IN THICK POLYTHENE SHEETS AND KEEPING SILICA

CRYSTEL BAGS WILL PREVENT INGRESS OF WATER /MOISTURE AND PROTECTION
FROM RAINS.

HEIGHT OF THE PACKING BOX IS VERY IMPORTANT FROM TRANSPORATION POINT

OF VIEW IN INDIAN CONTEST, THE CROSS BAR HEIGHT AT RAILWAY CROSSING IS
AROUND 16 FEET AND 3 INCHES. SIMILARLY STATE SEB’S SUB TRANSMISSION LINES
(INCLUDING SAG) HAS LOWEST HEIGHT OF 17FEET AND 3 INCHES. THEREFORE WHEN
LOADED ON A CARRIER, IF POSSIBLE, THE HEIGHT SHOULD BE LIMITED TO ABOVE
SPECIFIED LIMITS. OTHERWISE SPECIAL PERMIS SION WILL BE REQUIRED FROM
RAILWAY AND SEBS FOR TRANSPORTATION.

SEA WORTHY PACKING IS MANDOTARY IN CASE OF EXPORT JOBS WHICH

INVOLVES BUTT-JOINTS IN EACH WOODEN SLEEVE AS SHOWN BELOW. THIS TYPE
OF JOINT WILL REDUCE CHANCES OF INGRESS OF WATER DUE TO SEA WAVES
WHEN PACKING BOX IS ON BOARD OF SHIP.

IN ADDITION TO SEA WORTHY PACKING, BEFORE TAKING UP EQUIPMENT FOR

PACKING, IT HAS TO BE PACKED WITH THICK POLYPACKING A ND ANTI TERMITE
TREATMENT IS TO BE G IVEN TO THE PACKING FOR GERMS PROTECTION.

NOW A DAYS AT PORTS, CUSTOM AUTHORITIES WANT A PEEP WINDOW IN THE BOX
FOR PHYSICAL VERIFICATION OF EQUIPMENT AND THEREFORE PROVISION FOR
PEEP WINDOW IS ESSENTIAL.

16 STORAGE OF EQUIPMENT:-

ONCE PACKED GOODS ARE RECEIVED AT SITE , VISUAL INSPECTION OF PACKING

BOXES WILL REVEL WHETHER, THE CASE HAS BEEN RECEIVED WITHOUT ANY
TRANSIT PROBLEM. IF THE CASE SEEMS UNDAMAGED, IT IS REASONABLE TO
EXPECT THAT THE ENCLOSED M ACHINE HAS BEEN RECEIVED WITHOUT ANY
DAMAGE.

UNPACKING OF THE BOX TO RECEIVED PACKED MACHINE IS AN ART AND IS TO BE

DONE WITH SKILLED LABOURS. AFTER ARRIVAL OF PACKING, THE SAME SHOULD
BE EXAMINED TO DETERMINE WHETHER MOISTURE OF ANY KIND HAS ENTERED.
AFTER UNPACKING THE MACHINE SHOULD BE CLEANED FROM OUT SIDE AND
INSPECTED THOROUGHLY TO SEE NOTHING IS LOOSE OR DETACHED DUE TO

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 32

VIBRATION OR INTERFERENCE DURING TRANSIT.

IF THE MACHINE IS NOT TO BE INSTALLED IMMEDIATELY, IT SHOULD BE STORED IN

DRY, CLEAN SPACE DULY COVERED WITH POLYTHENE PACKING AND SHOULD BE
KEPT IN COVERED SPACE ALL ROUND. THE COVERED SPACE SHOULD NOT BE
SUBJECTED TO LARGE TEMPERATURE VARIATION.

THE CONDENSATION OF MOISTURE ON WINDINGS LOWERS THE INSULATION

RESISTANCE. EVERY MACHINE IS PROVIDED WITH SPACE HEATERS WHICH ARE
MEANT FOR BEING KEPT ON WHEN THE MACHINE IS NOT IN OPERATION AND EVEN
DURING STORAGE OR WHEN MACHINE IS NON OPERATIONAL. PROTECTIVE AXIAL
LOCK ING COVERS/EXTENSION G UARDS SHOULD BE USED TO PROTECT THE SHAFT
EXTENSION.

THE MACHINE SHOULD NOT DIRECTLY BE KEPT ON EARTHEN FLOOR AND IT

SHOULD BE SEEN THAT RELATIVE HUMIDITY DOES NOT EXCEED 70% AND
TEMPERATURE BELOW 10 DEG C. IS AVOIDED. STORAGE OF ACIDS/ALKILIES,
CHEMICALS DRUMS/TANKS SHOULD BE AVOIDED NEAR THE MACHINE.

BEARING PROTECTION DURING STORAGE

IF THE STORAGE OF MACHINE IS MORE THEN 2 YEARS (FROM THE DAY OF

COMMISSIONING) IT IS PREFERABLE TO RELUBRICATE THE BEARINGS(IT IS
ASSUMED THAT THE MACHINE IS STORED IN FAVOURABLE CONDITIONS).

HERE IN CASE OF ROLLER BEARINGS A PHENOMENON CALLED ”STATIONARY

VIBRATION” IS VERY IMPORTANT IN CASES WHERE MACHINE HAVING ROLLER
BEARINGS IS STORED IN A PLACE OF WHICH GOROUND IS SUBJECTED TO SOME
VIBRATION IN SHOP FLOORS. THIS IS ALSO CALLED STATIC VIBRATION OR FALSE
BRINELLING. DURING PROLONGED STORAGE DUE TO GROUND VIBRATION, THE
ROLLER BEARINGS ARE SUBJECTED TO THIS VIBRATION AND MAY CAUSE TO
DAMAGE TO THE BEARINGS. IN SUCH CASE FOLLOWING PRECAUTIONS
ARE ADVISABLE:-
A) IF POSSIBLE DO NOT STORE SUCH MACHINES ON VIBRATING GROUND.
B) IF THIS IS NOT POSSIBLE, STORE THE MACHINE ON RUBBER PADS/CORK/PADS AND
TURN THE ROTOR 90 DEG EVERY WEEK (i.e. full 360 deg in a month)

REQUEST MANUFACTURER/SUPPLIER TO KEEP A TLEAST ONE COPY OF MACHINE

DRG/OPERATING MANUAL IN THE PACKING BOX

17 GENERAL

MANUFACTURERS/SUPPLIERS GENERALLY PROVIDE OPERATING AND STORAGE

INSTRUCTIONS ALONGWITH DISPATCH DOCUMENTS AND OTHER TEST CERTIFICATES.
IT IS ADVISABLE TO GO THROUGH THE OPERATING INSTRUCTIONS AS SOON AS
THE EQUIPMENT IS RECEIVED AND FOLLOW THE INSTRUCTIONS IN THE BOOK LET.

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION

 33

GENERALLY BUYER TRIES TO AVOID CALLING REPRESENTATIVES OF SUPPLIER DURING

INSTALLATION. OUR SUGGESTION IS THAT EVEN IF BUYER HAS TO PAY FOR THE SERVICE
CHARGES FOR DEPUTATION OF SUPPLIER SERVICE ENGINEER, IT IS WORTHWHILE TO
CALL HIM SINCE ALL THE PRECAUTIONS ARE NOT POSSIBLE IN A WRITTEN DOWN
STATEMENT AND SUPPLIER REPRESENTATIVE WILL TAKE GREAT CARE SINCE
SATISFACTORY PERFORMANCE OF THE EQUIPMENT IS STILL THE RESPONSIBILITY OF
THE SUPPLIER TILL WARRANY PERIOD IS OVER.

-------------- END --------------------------

INTERNATIONAL INSTITUTE FOR ADVANCED TRAINING ON CONTROL AND AUTOMATION