H.T.

MOTORS

PREPARED BY ALOK KASTWAR (ENGR(OPRN.))

H.T.Motors
: Construction
: Working principle
: Cooling methods
: Losses and efficiency
: Protection Scheme
 ELECTRICAL MOTOR

Motors convert electrical energy into

mechanical energy by the interaction
between the magnetic fields set up in
the stator and rotor windings.

Input = Electrical Power

Output = Mechanical Power
 CLASSIFICATION

ALTERNATING CURRENT (AC), DIRECT

CURRENT (DC),UNIVERSAL
HT MOTORS, LT MOTORS, CONTROL
(SERVO MOTORS)
SINGLE PHASE, POLYPHASE(3PHASE)
USE : DUST PROOF, INDUSTRIAL MOTORS ,
MINING , MARINE APPLICATION ETC
 A.C. MOTORS
INDUCTION MOTORS
SQUIRREL CAGE 3Ph. WINDING IN STATOR
COPPER BARS IN ROTOR

WOUND ROTOR 3Ph WINDING IN STATOR

3 Ph. WINDING IN ROTOR
(SHORTED INTERNALLY)

WOUND ROTOR 3 Ph. WINDING IN STATOR

WITH SLIP RING 3 Ph. WINDING IN ROTOR
(TERMINATED TO SLIP RINGS)

SYNCHRONOUS MOTORS 3 Ph WINDING IN STATOR

DC WINDING IN ROTOR
(TERMINATED TO SLIP RINGS)
 HIGH TENSION OR HIGH VOLTAGE MOTOR
FEW SPECIAL FEATURES ARE

HEAVY DUTY MACHINES

HIGH VOLTAGE (> 1000 VOL.) /CURRENT RATINGS
BETTER METHOD OF COOLING
SPECIAL ENCLOSURES
UNIDIRECTIONAL MOTION
COSTLY
DIRECT ON LINE STARTING
(CIRCUIT BREKAER STARTED)
BIGGER BEARINGS
HIGHER CLASS OF INSULATION
HIGHER POWER RATING > 300KW
COMPREHENSIVE PROTECTIONS
 HT MOTORS IN NTPC KORBA
11 KV DRIVE – MDBFP ( Stage II)
6.6 KV DRIVES -
MAIN PLANT - ID FAN,FD FAN, PA FAN (Stage I/II)
BFP (Stage I),CC PUMP ,ARCW,
ECW P/P ( Stage II),
OFF SITE - IAC/PAC/TAC , LP ASH WATER P/P
ASH SLURRY P/P,CT/CW MOTORS
BOOSTER P/H, RAW WATER P/H,
DM PLANT
CHP - COAL CONVEYORS MOTOR
ALL THE H.T. MOTORS USED
IN KSTPS ARE POLYPHASE
INDUCTION MOTORS
(SQUIRREL QAGE TYPE)
 SYNCHRONOUS MOTORS INDUCTION MOTOR

1.Constant speed operation at all 1.Speed decreases with load

loads
2.No speed control (normally) 2.Speed control is possible
3.No self starting torque 3.Self starting
(external means required)
4.Maximum torque is 4.Maximum torque is
proportion to supply voltage proportional to square of voltage
5.Doubly excited 5.D.C. current not required for
6.Maintenance cost is high excitation
7.Costly 6.Simple, Rugged, Low maint.
8.Use 7.Cheaper
a. Power factor control 8.Use
b. Mechanical Loads Mainly for mechanical loads
Cement factory -Mills

>80% INDUSTRIAL MOTORS ARE POLYPHASE IND.MOTOR

SQUIRREL CAGE INDUCTION
MOTOR
CONSTRUCTION AND WORKING
PRINCIPLE
CONSTRUCTION FEATURE
STATOR – Stationary part
ROTOR – Rotating part
BEARINGS
END SHIELD/COVER, COOLING ARRANGEMENT
STATOR
STATOR
 STATOR
It consists of stator frame, laminated core and stator winding.

Stator frame is steel fabricated robust structure capable of

preventing deformation due to large electromagnetic forces

Low loss high grade pre-coated silicon steel sheet laminations

(0.5 or 0.65 mm thick) are assembled together to form laminated
core.

The laminated core along with the winding is pressed into the stator
frame and locked against the rotation and axial displacement

The stator winding of the motors is provided with Class-F insulation

system
STATOR

The winding is a chorded double layer winding.

The windings consist of three sets of coils separated 120 degrees
electrical
The conductor strands consist of electrolytic copper and taped
with epoxy mica paper tape having high dielectric strength to
provide inter- turn insulation.
The coils are inserted in the open slots of laminated core.
The slots are normally closed by magnetic wedges/ putty.
SQUIRREL CAGE ROTOR
SQUIRREL CAGE ROTOR

The rotor winding consists of sectional bars of copper or

its alloys, which are firmly seated in the slots of the rotor
core using steel liners.

The bars are brazed to short circuiting rings.

Bars tightness in the slots is ensured for long

uninterrupted running of the motor.
 HT MOTOR TERMINAL BOX
Motors are normally provided with Phase-segregated terminal box which
has been standardized.This design minimizes the possibility of a
fault and ensures that a line to line fault cannot develop

Main terminal box can be provided with suitable gland or glands for
entry of one or more single or multiple core cables in accordance
with the specific needs

It is a usual practice to have star connection for stator winding and take
out all the six leads. This facilitates fault detection and also
incorporation of additional euipment like Current Transformers
for Differential Protection on neutral side, if needed.
 BEARINGS
ROLLING BEARINGS
In case of machines with antifriction bearings, a deep groove ball
bearing is paired with the cylindrical roller bearing at one end to provide
location to the shaft and the roller bearing at the other end.
The rolling bearings are fitted with V -type rotating axial shaft seals.
This seal prevents the penetration of dust and water, and extends the life
of the bearing as well as the re-greasing intervals.

SLEEVE BEARINGS
The sleeve bearings become necessary for applications beyond the
capability of anti- friction bearings, that is, for higher speed loads and
other operating conditions.
When correctly maintained, sleeve bearings have practically
unlimited service life.
Sleeve bearings are normally of floating type.
 3 phase winding
120 ‘ spaced
3 phase
Balanced
A.C.
supply

Rotor

C.B Stator
2 Pole
Air Gap

Space distribution of MMF

along air gap periphery
 Synchronously Rotating
Magnetic Field

3 phase
Balanced
A.C.
supply

C.B Stator
2 Pole

N pole

S pole
 Magnetic Field cutting Rotor

3 phase
Balanced
A.C.
supply

ROTOR

C.B

Stator
N pole
Air Gap
S pole
 BASIC CONCEPT OF MOTOR
STATOR ROTATING FIELD CUT ROTOR CONDUCTOR AT SYN. SPEED
SYN.SPEED = (120 X SUPPLY FREQUENCY) / NO.OF POLES
(FOR 50 Hz MOTOR SYN.SPEED = 6000 / NO.OF POLES)
AN E.M.F (ELECTROMAGNETIC FORCE) IS PRODUCED IN ROTOR
THIS E.M.F. CIRCULATES A CURRENT IF ROTOR CIRCUIT IS CLOSED
THIS CURRENT PRODUCES ITS OWN MAGNETIC FIELD

THIS MAGNETIC FIELD OPPOSES STATOR MAGNETIC FIELD & TRY

TO REDUCE ITS EFFECT, EFFECT OF STATOR FIELD IS DUE TO
DIFFERENCE IN SPEED OF STATOR MAGNETIC FIELD AND ROTOR
SPEED,CALLED SLIP SPEED

SLIP SPEED = SPEED OF STATOR FIELD – ROTOR SPEED

SO ROTOR STARTS ROTATING SUCH THAT THIS SPEED

DIFFERENCE SHOULD REDUCE AND TRY TO CATCH STATOR
ROTATING FIELD
 ROTOR STARTS ROTATING
IN THE DIRECTION OF FIELD

3 phase
Balanced
A.C.
supply

ROTOR

C.B

STATOR
N pole
Air Gap
S pole
 FACTS ABOUT INDUCTION MOTOR

The induction motor may be regarded as a

‘constant speed’ machine
Other key features:
The maximum speed is a synchronous speed, N s,
independent of the applied voltage
Torque is proportional to the V2 at an arbitrary
speed
When operating at 90-95% Ns heat losses are at
minimum
 TYPE OF ENCLOSURE/COOLING
METHOD
i. Drip proof Screen Protected ( DPSP)
ii. Totally Enclosed fan ventilated -TEFC
iii. Totally Enclosed closed air circuit air cooled
integral Heat exchanger - CACA
iv. Totally Enclosed closed air circuit air cooled
machine mounted Heat exchanger
v. Totally Enclosed closed air circuit water cooled
integral Heat exchanger -CACW

COOLING METHOD USED FOR HT MOTORS

CACA & CACW ( MDBFP , ID FAN Motor)
 TYPE OF MOTOR ENCLOSURES AS PER
DEGREE OF PROTECTION
General suffix letter for protection IP x y
X:
0 Non protected
1, 2, 3 Protected against solids > 50 mm, 12mm, 1mm
5 Protected against dust
Y:
0 Non protected
1 against dripping water
2 against drops of water up to 15 deg from vertical
3 spray 4 splashing water
5 water jet 6 Ships deck
7 Effects of Immersion 8 submersible

Normally used enclosures are of IP55/IP54 for HT Motors

 METHOD OF COOLING AS PER IS6362/ IEC34- 6 APPLICABLE FOR A.C. MACHINES

COMPLETE DESIGNATION : IC 8 A 1 W 7

SIMPLIFIED DESIGNATION : IC 8 1 W
METHOD OF MOVEMENT OF
INTERNATIONAL COOLING SECONDARY COOLANT

1- SHAFT MOUNTED FAN

CIRCUIT ARRANGEMENT
6- SEPARATELY DRIVEN FAN
0 - SPDP (OPEN CIRCUIT) 7- WATER DISTRIBUTION
3 – DUCT VENTILATED (OPEN CIRCUIT) SYSTEM
4 – SURFACE COOLED
RIBBED SURFACE SECONDARY COOLANT
PRIMARY COOLANT ( CLOSED CIRCUIT)
A- AIR
SECONDARY COOLANT (SURROUNDING MEDIUM)
W- WATER
5 – TETV
HEAT EXCHANGER INTEGRAL METHOD OF MOVEMENT
PRIMARY COOLANT ( CLOSED CIRCUIT) OF PRIMARY COOLANT
SECONDARY COOLANT (SURROUNDING MEDIUM)
6 – CACA 1- SHAFT MOUNTED FAN
HEAT EXCHANGER ( MACHINE MOUNTED)
PRIMARY COOLANT ( CLOSED CIRCUIT) 6- SEPARATELY DRIVEN FAN
SECONDARY COOLANT (SURROUNDING MEDIUM) 7- WATER DISTRIBUTION
8 – CACW
HEAT EXCHANGER ( MACHINE MOUNTED) SYSTEM
PRIMARY COOLANT ( CLOSED CIRCUIT)
SECONDARY COOLANT
(REMOTE MEDIUM e.g WATER)
PRIMARY COOLANT

A- AIR
W- WATER
Totally Enclosed closed air circuit air cooled
integral Heat exchanger - CACA

Cooling Ducts/path along

Cold Air
motor stator
inlet

Cooling fan
mounted on
motor shaft
FD FAN (Stage II)
Totally Enclosed closed air circuit air cooled
integral Heat exchanger - CACA

Cold Air I/L

Cooling Ducts/path along

motor stator
Hot air out
Totally Enclosed closed air circuit water cooled integral
Heat exchanger - CACW
CW I/L

CW O/L

2 no. of Coolers

Cooling fan 2
no.s (DE/NDE)
mounted on
motor shaft
BFP ( Stage I)
Totally Enclosed closed air circuit air cooled
ntegral Heat exchanger - CACA

Cooling Ducts/path

Cooling of Stage I Cold Air I/L

motors(similar to
ARCW P/P of Stage II) External fan mounted at fan
NDE side
Totally Enclosed closed air circuit air cooled
integral Heat exchanger - CACA

Hot air out

Fan (DE side)
 LOSSES IN MOTORS

Power i/p to stator from mains

Power from
rotor shaft

Stator Stator Rotor Rotor Rotor Friction Windage

Copper core i/p Coppercore loss at loss
loss loss power loss loss Bearings
Or
Air
Gap
power
 LOSSES IN MOTORS
1Core losses - A combination of eddy - current and hysterisis losses
within the stator core. Accounts for 15 - 25 percent of the overall
losses.
2 Friction and Windage losses - Mechanical losses which occur due
to air movement and bearings. Accounts for 5-15 percent of the
overall losses.
3 Stator losses - The I 2 R (resistance) losses within the stator
windings. Accounts for 25 - 40 percent of the overall losses.
4 Rotor losses - The I 2 R losses within the rotor windings. Accounts
for 15 – 25 percent of the overall losses.
5 Stray Load losses - All other losses not accounted for - Accounts
for 10 – 20 percent of the overall losses.
As the load on the motor is reduced, the magnitude of the active current
reduces. However, there is not a corresponding reduction in the
magnetizing current, with the result that the motor power factor reduces,
or gets worse, with a reduction in applied load.
PROTECTIONS OF H.T. MOTORS
 PROTECTIONS OF H.T. MOTORS
Electrical protection
 Over Load ,Earth Fault ,Under Voltage etc.
Mechanical protection/C & I protection
Since driven equipment is directly coupled with Motor ,
anything goes wrong with this equipment may severely hurt
Motor. Few examples are
 Lub. Oil pr. Low –Low (ID fan/MDBFP motor)
 Bearing temperature Hi –Hi (PA fan etc)
 Discharge damper closed while fan running (ID fan
etc)
 High Vibration
 OBJECTIVES OF PROTECTION

Motor’s normal life is 20 years.

Motor has to be protected against many

hazards in working environment which
can damage or reduce its life considerably.

Motor should be made to deliver its output

with least stress on its performance specs
despite abnormalities in working environment
Why Protect Motors
Other Sources of faults in a Motor……
MOTOR INDUCED
SYSTEM INDUCED
INSULATION FAILURE
SINGLE PHASING
BEARING FAILURE
PHASE REVERSAL
LOSS OF FIELD(S/M)
U/V , O/V
HIGH INERTIA
VOLTAGE UNBALANCE

LOAD INDUCED
OVER LOAD USER INDUCED
ROTOR JAMMING REPEAT STARTING
OUT OF STEP (S/M) WRONG CONNECTIONS
WRONG SETTINGS
ENVIRONMENT INDUCED POOR MAINTANENCE
HIGH AMBIENT TEMP
DAMPNESS
 Causes of Motor Failure
Cause Conributio
Persistant O/L 7%
High Amb Temp 8%
Abnormal Moisture 18%
Abnormal Voltage 5%
Abnormal Frequency 1% Persistant O/L High Amb Temp
High ibration 9% OTHERS 7% 8%
Aggressive Chemicals 7% 14%
Poor Lubrication 5%
Poor Ventilation / cooling 8%
Normal deterioration with age 18%
OTHERS 14%

Normal deterioration
with age Abnormal Moisture
18% 18%

Poor Ventilation /
cooling
8% Abnormal Voltage
5%

High ibration
Abnormal Frequency
9%
Poor Lubrication Aggressive Chemicals 1%
5% 7%
 Motor Protection - Practices

LESS THAN 10 kW BIMETAL RELAY

10 KW TO 50 KW BIMETAL + SINGLE PHASING

50 KW TO 100 KW THERMAL O/L + O/C +E/F+

UNBALANCE+LOCKED ROTOR

100 KW AND ABOVE COMPREHENSIVE

MOTOR PROTECTION RELAY
THERMAL O/L+O/C+E/F+
UNBALANCE+REPEAT STARTS+
+UV

SYNCHRONOUS MOTORS ABOVE PROTECTIONS+ U/V+

(1 MW AND ABOVE) DIFFERENTIAL+ROTOR E/F+
UNDER EXCITATION+OUT OF STEP
 PROTECTIVE RELAYS

•Protective relays are devices that detect abnormal conditions

in electrical circuits/equipments by constantly measuring the
electrical quantities which are different under normal & faulty
condition.
•The basic parameters which may change in fault condition
are Voltage, current, frequency, Phase angle etc.
•After detection of the fault , the relay operates to complete
the trip circuit to open the on load isolation switch thereby
isolating the faulty part of the equipment
 BASIC PROTECTION CIRCUIT

CT Circuit Breaker

Fixed Contact Moving Contact

PT Protecting Trip
System
Abnormal
Condition

OVER CURRENT PROTECTION

HT MOTOR PROTECTION IN KSTPS

1. Over Load
2. Earth Fault
3. Differential protection
4. Under Voltage (Bus)
5. Stalling/Locked Rotor
6. Over Load Alarm
CURRENT UNBALANCE
When supply current is not balanced
Negative phase sequence (2f component) may flow This causes
overheating
This Negative phase sequence current flows opposite to rotor
rotation at twice of supply fequency
Bearings can suffer damage due to 2f component
1% Voltage unbalance can result in 3 to 5% increase in motor
currents,3% Voltage unbalance can cause up to 25% increase in
motor temperature

Heating Current I = Id2 + 3 Is2

Id – Positive sequence current
Is – Negative sequence currennt
SINGLE PHASING (LOSS OF SUPPLY ON ONE PHASE)

This is the worst condition of

phase unbalance. It may occur
when protective fuses are blown
or CB all pole phase not operate.
When Single phased in any one of
the lines,Current in the other two
phases can go to 1.73 times the
normal rated current
(2 times if poor PF)
Again this condition will result in
overheating and subsequent
deterioration of motor life. If
undetected for too long it will
most likely cause burn out.
OVERLOADING
Excessive current in circuit resulting in overheating and deterioration
of machine life.

STALLING (STATIONARY ROTOR)

This condition occurs when the motor cannot drive its connected
load. Excessive heating again occurs causing machine life
deterioration and/or burn out.

RECLOSING OF SUPPLY SHORTLY AFTER INITIAL LOSS

OF ELECTRICITY.
This condition may be specially dangerous to motors driving
compressor loads as re-energizing the motor under heavy load could
cause overheating resulting in deterioration of motor life or burn out.
Typical Thermal Over Load Curves

t
Cold Curve

Hot Curve

I/Im
1.05 2.0 3.0 4.0 5.0 6.0
 MOTOR STARING CURRENT
TYPICAL CHARACTERISTICS
Motor Current
Starter Ist tst
DOL 6Im 3 sec
Ist
Ist – Starting Current
Im – Full Load Current

Im

Time

tst
LOCKED ROTOR /STALLING (ROTOR
STATIONARY) PROTECTION
-When any motor is started, it may not be able to drive the
connected load, its rotor does not rotate or locked to its stationary
position either because of mechanical jamming or heavy load or any
other reason. Same conditions may occur during normal running
condition and the motor may stall.
-The motor draws heavy current may result in heavy
heating/burning of motor
-To protect motor from above conditions Locked rotor protection is
provided
-Criteria for providing the protection is purely depends on Nature of
Load having long starting time /Past experiences of manufacturer
-The protection incorporated in
Stage I - PA FAN
Stage II - ID FAN , PA FAN
CHP - Conveyor motors
LOCKED ROTOR /STALLING (ROTOR
STATIONARY) PROTECTION

RELAY OPERATION (Relay Stage I )

Protection taken from STARTING CURRENT & TIME
It has 2-timer circuit
1.Starting timer – While starting
2.Trip timer – While running normal
Current/Time setting is less as compared to other relays

RELAY OPERATION (Relay Stage II)

Protection taken from sensing Actual SPEED OF ROTOR
Relay energizes sensing Circuit Breaker closing contact and gives
trip command if rotor does not start rotating( during starting) or
stops ( while running) & Rotor rotation is sensed by Tachometer/coil
Mounted on rotor shaft for sensing speed
 DIFFERENTIAL PROTECTION
Basically it is a name of the scheme

Whenever the vector difference of two similar quantity

exceeds a certain pick up value a signal generated that can be
used for tripping the drive

It takes care of IN ZONE fault of machine e.g. E/F, Inter-turn

fault, Phase to phase fault

It does not respond to fault lies out of its zone of

protection

Provided in Costly and Heavy duty drives e.g. MDBFP

(Stage I/II), PA/ID fan (Stage II)
 DIFFERENTIAL PROTECTION
Protected zone

System To Be
Protected

In Zone Fault

I1 I2

Relay Restrains Relay Operates

I1 - I2 = 0 I1 - I2 > 0
 OVER CURRENT RELAY/HI SET

-Hi Set is basically Inverse time type O/C relay, operating

time of which reduces as current rises
( i.e. Time of operation is less for higher current)

-Relay operates on the characteristic of fault current

-Takes care of O/C, Phase to phase faults etc

.
-Provided in all motors not having Differential protection
 EARTH FAULTS

-E/F occurs when any current carrying conductor finds

path to Earth.
-Electrical motor draws heavy current resulting in
burning of winding if not got disconnected from supply
source
- E/F relay operates on the basis of Residual current
through neutral of CT connected in protection circuit

Normally Ia + Ib + Ic = 0
During fault Ia + Ib + Ic > 0

-Relay is set to pick up this residual current and gives

trip command to motor
 OVER CURRENT TIMER/ALARM

Incorporated in Y phase
(same current that UCB ammeter shows)

Once current starts increasing from its normal value, a timer

starts counting when this current sustained for certain
period (e.g. 3 Sec. in case of ID fan (Stage II)) an alarm of
Overload is generated that normally appears in UCB.
 UNDER VOLTAGE TRIP
Not given for a particular drive
Applicable for Supply Bus (i.e. if bus voltage falls
When Bus voltage comes down below a certain value
(normally 70% of Rated Bus voltage) Under Voltage trip
relay gives trip command to all drives fed from bus
Relay associated with a TIMER which takes care of
Momentary dip in Bus voltage due to some disturbance
ORIGINAL PROTECTION SCHEME OF ID FAN (STAGE II)

Measuring CT
A Ammeter at breaker panel

O/L O/L LOCKED EARTH

TRIP ALARM ROTOR FAULT
ITGL ITG ITM IAG
7221 7113
7119 7221

R
Y
B

Protection CT
RYB
RELAY PANEL (PA FAN STAGE II)
 STAGE II RELAYS
FEEDER/EQUIPMENT RELAY DESCRIPTION
Mills, CC p/p, FD fan ITGL 7261 O/C 3 PHASE
ARCW, ECW, CEP, ITG 7113 O/L ALARM
PAC, IAC IAG 7014 E/F TRIP WITH RAD
LP ash water p/p RAD 7004 LOCKOUT RELAY

ID Fan IAG 7034 DIFFERENTIAL RELAY

PA fan ITGL 7221 O/C 2 PHASE
ITG 7113 O/L ALARM
IAG 7014 E/F TRIP WITH RAD
ITM 7119 LOCKED ROTOR PROT
RAD 7004 LOCKOUT RELAY

Bus Under Voltage ITG 7013 BUS U/V

protection TTT 7111 TIMER
TAA 7030 MOTOR LOAD SHEDDING
TRIP AT 70% VOL.
 STAGE I (RELAYS)
FEEDER/EQUIPMENT RELAY DESCRIPTION
FD fan Mills, CEP, TMAS 311 O/C TRIP
PAC, IAC TMA111 O/L ALARM
PA Fan CAG 12 E/F TRIP WITH RAD
50 LR/2LR LOCKED ROTOR(PA Fan only)
86 LOCKOUT RELAY
ID Fan TMAD DIFFERENTIAL RELAY
TMAS 311 O/C TRIP
TMA111 O/L ALARM
CAG 12 E/F TRIP WITH RAD
86 LOCKOUT RELAY

Bus Under Voltage VAG 31 BUS U/V

protection TMV 311m TIMER
VAJ MOTOR LOAD SHEDDING
TRIP AT 70% VOL.