Machines for potentially explosive atmospheres

Performance, Reliability, Safety

Presentation index
- Hazardous area classification
- VFD operated machines
- Ex portfolio
- Certifications
Hazardous area classification
Summary of Basic definitions - IEC
 Equipment groups
 Group I - Mines susceptible to firedamps Equipment Category for GAS
 Group II – Surface plants with explosive GAS Ex db
 Group III – Surface plants with explosive DUST Ex eb
Not suitable for
 Zones GAS (DUST) electric motors Ex pxb
 Zone 0 (20) - continuously
 Zone 1 (21) - occasionally
 Zone 2 (22) - in abnormal conditions Ex ec
 Gas groups Ex pzc
 IIA (e.g. Propane)
 IIB (e.g. Ethylene)
Equipment Category for DUST
 IIC (e.g. Acetylene and Hydrogen)
Ex tb
 Dust groups
Not suitable for
 IIIA (combustible flying) electric motors
 IIIB (non-conductive dust)
 IIIC (conductive dust)

 Temperature Classes Ex tc
T1 T2 T3 T4 T5 T6
450°C 300°C 200°C 135°C 100°C 85°C Ex eb only for T1-T3
Potentially explosive atmosphere
Ex Protection Types in motors

Pressurized p Dust t
Flameproof d

Increased Safety e
Changes in Ex markings

Old marking New marking

Ex nA Ex ec
Ex e Ex eb
Ex d Ex db
Ex pz Ex pzc
Ex px Ex pxb

November 2, 2020 Slide 5

Basic principles Ex p

po
Outlet po : atmospheric pressure
No spark in inert gas
normal/ fault p : pressure inside enclosure
conditions
No dangerous hot
p > po surfaces under all
conditions

 What does pressurized protection mean?

 Parts which could ignite an explosive gas mixture are housed in
an enclosure flushed and pressurized by a protective gas, e.g.,
clean air
 The outer parts of the motor do not spark or do not have hot surfaces.
 Ex p Protection
IEC60079, ATEX Directive 94/9/EC and EN 60079-2:

Ex pxb :
– Applicable to be installed in Zone 1 & Zone 2
– The overpressure must be at least 50 Pa
– Main terminal boxes are pressurized NOTE! For both ABB pxb and pzc
Ex pzb: motors, the min overpressure is
– Applicable to be installed in Zone 2 only 100 pa (1 mbar)
– The overpressure must be at least 25 Pa
– Main terminal boxes are pressurized
Ex pxb eb/ Ex pzc ec:
– Same with Ex pxb / Ex pzc, except that main terminal boxes are Ex e approved instead of Ex p approved (pressurized).

November 2, 2020 Slide 7

 Ex p Main Components

Control unit and Relief valve

- Delivered by Expo

Piping system
- stainless steel

Min pressure detector

Acessories
- special orders

Typical pneumatic concept

November 2, 2020 Slide 8

Critical parts in Ex-machine (Ex e, Ex p, Ex t)
Ex auxiliary components

Clearances and creepage Earthing and equipotential

distances in terminal boxes bonding

Air gap between Clearance between

rotor and stator fan and fanhood

Degree of protection Special materials

Construction of
Temperature rise
rotor and stator
Ex Safety with motors fed by VSD´s

1. Electrical protection
– Sparks
• Bearing current
• Stator insulation
• Terminal box
– Thermal sensor for electrical
overload protection
2. Surface temperature
protection
– Dimensioning
– Thermal sensor for surface
temperature
– VSD current limit

A standard cage induction motor’s typical loadability in a frequency

controlled drive 1) without separate cooling and 2) with separate cooling.
Stator insulation

VSD creates continuously high voltage

peaks
Insulation material:
– Pk-pk Phase-ground voltage
– Impulse repetition rate
– Rise time of impulse
– Jump voltage (for multi-level drive)
Typical High voltage insulation system

Schematic picture of machine insulation system:

1 main insulation; 2 conductor insulation; 3 end corona protection;
4 slot corona protection; 5 surface tape; 6 bracing; 7 slot wedges
Bearing Current
The VSD might generate high
frequency current in the bearings
Bearing current might create
sparks in the bearings and outside
the frame
Sparks may damage the bearings,
lubrication or they can ignite
explosive gas around the motor
ABB documents indicates how to
prevent that phenomena
– Bearing insulation
– Cabling, grounding
2-pole motors for VFD
Non-stiff shaft motors, type AMI
– Power ranges from 2 to 7 MW
– Speed ranges up to 3600 rpm

Stiff shaft motors, type AMI

– Power ranges from 2 to 6 MW
– Speed ranges up to 4000 rpm
– Critical speed clearly outside speed range
Well suited for VFD applications
Bearing alternatives
The choice of bearing arrangement is based on
following basic factors
n [rpm] overlapping area
– load carrying capacity
3000
– overspeed and duration
1500
– rotating speed Anti-friction
– bearing life
1000 bearings
– operating temperature
– dirt, dust or other small particles in the air
750
– vibrations and shocks effecting bearings when they are
not running
600
Sleeve bearings
500
429
0 1 2 3 4 5 6
P [MW]
Large Motors and Generators-Vadodara
Engineered product range

AMI (Engineered Modular Motors)

• 160 kW-11000 kW, 50/60 Hz, Low voltage to 13.8kV

• Poles 2-20 - Horizontal / Vertical Mounting
• Fixed / Variable Speed
• Shaft heights - 400 to 710 mm ,
• Enclosure - CACA, CACW and SPDP

November 2, 2020 16
Large Motors and Generators-Vadodara
Engineered Product range

HXR (Engineered Cast Iron Motors)

• 160 kW-1400 kW, 50/60 Hz, Low voltage to 11kV
• Poles 2-12 - Horizontal / Vertical Mounting
• Fixed / Variable Speed
• Shaft heights - 355 to 500 mm
• Enclosure – TEFC

AXR (Next Generation Rib cooled Motors)

• 125 kW-1600 kW , Low voltage up to 11 kV
• Poles 2-12- Horizontal / Vertical Mounting
• Fixed/Variable Speed
• Shaft heights – 315 to 500 mm
• Enclosure – TEFC

November 2, 2020 17
Large Motors and Generators-Vadodara
General Purpose Product Range

NXR (Next Generation Rib cooled motors)

• 125 kW-1600 kW , Low voltage up to 11 kV
• Poles 2-12- Horizontal / Vertical Mounting
• Fixed/Variable Speed
• Shaft heights – 315 to 500 mm
• Enclosure – TEFC

NMI (Next Generation modular construction motors)

• 550 kW-8000 kW , Low voltage up to 11 kV
• Poles 2-12, Horizontal / Vertical Mounting
• Fixed/Variable Speed
• Shaft heights- 400 to 630 mm
• Enclosure - CACA , CACW and SPDP

November 2, 2020 18
NMK slip ring induction motors Vadodara range

NMK (New Generation of Slip-ring motors)

• Output power: Up to 8000 kW
• Frame size: 400 to 630

• Number of poles: 4 to 8 (Upto 500 frame) & 4 to 12 (in 560 & 630 frame)

4 to 11 kV (Up to 500 frame) & 2.3 to 13.2 kV (Up to 630

• Voltage:
frame )
• Frequency: 50/60 Hz
• Cooling: IC611, IC616,IC81W*,IC86W*
• Protection: IP55
• Mounting: Horizontal
• Bearings: Antifriction, Sleeve*
• Insulation class: F
• Standards: IEC (electrically NEMA feature available)
• Supply: DOL

* Only available in 560 & 630 frame size

November 2, 2020
19
Ex Machine Offerings from Vadodara
Standards IEC/EN 60079-7/31

Level of protection ec/t as Level of protection eb as Level of protection P as

per IEC 60079-7/ 31 per IEC 60079-7 per IEC 60079-2

– 2 to 20 poles – 2 to 20 Poles – 2 to 20 poles

– Rated output PN upto 10 MW – Rated output PN upto 7MW – Rated output PN upto 11 MW
– Rated voltage UN above up to – Rated voltage UN above up to – Rated voltage UN above up to
13.8 kV 6.6 kV 13.8 kV
– TEFC, CACA, CACW – TEFC, CACA, CACW – TEFC, CACA, CACW
– 315 to 710 frame size – 315 to 710 Frame size – 315 to 710 frame size

November 2, 2020
Ex Machine portfolio - Global offerings
Standards IEC/EN 60079--

Level of protection ec as Level of protection d as per Level of protection p as

per IEC 60079-7 IEC 60079-1 per IEC 60079-2

– Rated output PN upto 75 MW – Rated output PN upto 8MW – Rated output PN upto 75 MW
– Rated voltage UN above up to – Rated voltage UN above up to – Rated voltage UN above up to
13.8 kV 11 kV 13.8 kV
– TEFC, CACA, CACW – TEFC, TETV – TEFC, CACA, CACW
– 315 to 2500 frame size – 355 to 900 Frame size – 355 to 2500 frame size

November 2, 2020
Hazardous motors with VFD
Protection ACS ACS1000 ACS2000* ACS5000
600/800/880

Ex ec (nA) Available Available Available Available

Ext (DIP) Available Available Available Available

Ex d Available Available Available Available

Ex p Available Available Available Available

Ex eb (e) Available for Available Available for Available

manf. for manf. manf. for manf.
machines machine machines machines
s

ABB Machines + Drives are already Atex and IEC Ex certified.

INABB – Has CCOE CERTIFICATION for Ex ec (nA) & Ex p for
complete range of machines along with ABB Make drives.
World of standards
IECEx (worldwide)

Other standards and

specifications:
National standards, like BS, DIN, SFS
etc.
Industrial specifications, like API,
Shell DEP etc
Inmetro
CEC, CSA
NEC, CSA/US/UL
ATEX (Europe)
TR CU
SABS
CCoE
CNEx
ANZEx
Korean Std

November 2, 2020 Slide 23

Certification for explosive atmospheres motors
Global vs. National certificates

Certifications used as global

CSA/CEC
EN
– IEC Code
NEMA
– IECEx System /NEC

– ATEX for EU
– CSA
AS/N
Typical national certificates ZS

– TR CU Russia, Kazakhstan and Belarus

– Inmetro to Brazil
– CNEx for China
– KOSHA for Korea
– CCoE for India

November 2, 2020 Slide 24