‘International Journal of Research in Electrical & Electronics Engineering Bas ‘Volume 1, Issue 2, July-September, 2013, pp. $462, 0 TASTER 2013 i@i ‘www-laster.com, ISSN Online: 2347-5439, Print: 2348-0025 4 Testing of Increased Safety HT Induction Motor for Hazardous Area Bhagirath Ahirwal' and Dr. Tarun Kumar Chatterjee” ‘Senior Scientist, Flame & Explosion Lab., CSIR-Central Institute of Mining & Fucl Research, Dhanbad, India Professor, Electrical Engineering Department, Indian School of Mines, Dhanbad, India ABSTRACT Testing is mandatory 10 know the performance of the designed any product. High Tension (HT) increased safety (Ex €) motors are being designed for safe operation iat the hazardous area. The increased safety motor is requiced some special test as per ISIEC 60079-7. The all relevant tests has heen conducted successfully at BHEL, Bhopal on designed Ex ¢ HT squirrel cage three phase induction motors rated 810KW/6.6KV/16 pole/ SOFz, 97OkW/6.6k VHS pole/ SOH: and 2200KW/5.6KV/2 ‘poles SOHz. Keywords: increased safety motor, special test, routine test, type test, impulse voltage test. 1. INTRODUCTION ‘Manufacturers are manufacturing wide range of electrical motors satisfying end uscr requirements of motive power from all sectors like steel, cement, power plant, petrochemical, refinery, mining, fertilizers, irrigation ete, The range of the motors vary from frictional horse power to mega horse power rated form single phase to three phase and low voltage to high tension. The motor is designed for hazardous area is a special type. It needs more attention and expertise ta design a motor in proper ‘way which can withstand all necessary tests for hazardous areas. The enclosures of such motors are dependent on the requirement of use and installation environmental arcas and they should have good degree of ingress protection for weather proofness. The testing of motar is mandatory to know the performance of the motor before installation and also to compare the technical design data with testing data of a particular motor. In this paper. some relaicd test on designed 810kW/6,6kV/I6 pole, ‘970KW/6.6kVF18 pole and 2200kW/6.6kV/2 pole Ex e HT motors are discussed. 2. TESTING AND ASSESSMENT OF EX E MOTOR “The designed Ex ¢ HT squirrel cage induction motor are tested and assessed for performance of motor toccnsure that these designed motor will not be unsafe in hazardous area. The tests and assessment for the Ex © motors are as follows: 2.1. Routine Test of Exe HT induction motor i, Measurement of resistance of windings ii, Insulation Resistance Test ii, Polarization index Measurement iv. Phase Sequence with respect to direction of rotation (DOR)International Journal of Research in Electrical & Electronics Engineering ‘Volume-1, Iseue-1, July-September, 2014, www daster.com (0) 2347-5439 ISSN AP) 2343-0025, y. No load test ‘vi. Measurement of vibration ‘Measurement of shaft voltage during no load test ix. AC High Voltage test 2.2 Typetest of Ex e HT induction motor ‘All tests included under Routine Test Locked rotor test at 200%, 150% and 100% of rated current ii, Temperature rise test iv. Momentary over load ¥. Over speed test vvi. Noise level measurement 2.3. Special Test of Ex ¢ HT induction motor i, Impact Test ii, Impulse voltage Test assessment iti, High voltage test assessment iv. Test for degree of Ingress Protection by enclosure 3. MEASUREMENT OF RESISTANCE OF WINDINGS ‘The cold resistance of stator winding is measured phase to phase at ambient temperature for all three ‘motors and average value of cold resistance of stator winding is given in the Table 1 ‘Table 1: Values of stator winding resistance “Motor Desai Cold resistance in) | Ambient wemperaume °C ‘SIOKWi6.6KV716 pole .i83 31.80, ‘BIOKWI6SKVAIS pole O28 2a 200K Wi6GK VA pole B.0607 ah 4. INSULATION RESISTANCE TEST ‘The insulation resistance (IR) was measured between winding and frame (earth) for all three Exe HT ‘motors at SEV by megger for one minute as per ISMEC 6034-1 and the values of IR: are given in the bbelow Table 2. ‘Table 2: Values of IR Motor Detail ‘Minimum IR value as per] IR value im) Wihsianding ISMIEC 6034-1 Mo time MORWIGGKVA6 pole 250 MO ‘6190 | One minute STOKW/6.6KV/I8 pole 250 MQ. 1490 | One rine 2200K Wis, 6KV2 pole 250 MO. 2310 [One minute 5. HIGH VOLTAGE TEST ‘The high voltage (HY) test was performed successfully between stator winding and frame of motor and phase to phase for all the Exe HT motors for one minute as per IS/IEC GO034-1 and the details is sgiven in the below Table 3. Two phases were connected to frame which in tum is earthed. The applicd 55International Journal of Research in Electrical & Electronics Engineering ‘Volume-1, Iseue-1, July-September, 2014, www faster.com (0) 2347-5439 ISSN AP) 2343-0025, ‘voltage is (twice of rated voltage of motor + 3) kV. SOHz. The voltage was gradually increased in steps of not more than 5% of the full value and full voltage had reached well within 10seconds. Table 3: Values of high voltage test ‘Motor Detail Location HY value in EV aa | Withstanding time IOKW/6.6KV/IGpale | Stator winding and frame 162 ‘One minute SOKWI66KV/IS pole | Phase to phase ROOKWIEEKV2 poke | stator winding and frame 162 (One minute BIOKW/G6KV/1G pale [Phase to phase TOKWISGKV/IS poke | stalor winding and frame Ted ‘One minute ‘Phase to phase 6, OVER SPEED TEST ‘The motor is designed to withstand a momentary over speed without mechanical injury in accordance with IEC 6034-1. The over speed test was performed at 120% of rated speed of the motor and it was conducted on each motor as per IS/IEC 6034-1. No movement in fly whee! position and no abnormality in other parts was observed during the test in any motor. The detail of test is tabulated in the Table 4. ‘Table 4: Detail of over speed RPM Motor Deal Speed of mowria RPM | Over speed in | Wahsianding RPM time BIORWISGRW/IGpare | S72 450 ‘Two minutes TKWEGKWIs pole [330 200 Two minutes DNOKWAEKWE pale [2972 2092, Two minutes 7. POLARIZATION INDEX TEST ‘tis the ratio of IR value measured at the end of one minute to IR value measured at the end of ten ‘minutes. The insulation resistance (IR) was performed oa all the stator winding for Exe HT motors at ‘SKV by megger for one minute as per IS/IEC 60034-1 and calculated values of polarization index is given in the below Table 5. The recommended minimum valuc of polarization index is 2 as per IS 7816. ‘Table &: Detail of polarization index values of Exe HT motors “Matar Detail TR value in MQ at [TR value in | Polarization | Minimum the end of Imi, MOQ at the end | Index Polavization Index as. of 10min. porls 7816 BIOKWIEEKWIG | 6190 "38000 cary z pale TOKWIEEKWAS | 1490 500 73 z ‘pole ROOKWISSKVA | 2310 T0200 az z pole 56International Journal of Research in Electrical & Electronics Engineering ‘Volume-1, Iseue-1, July-September, 2014, www faster.com (0) 2347-5439 «By 2348-0025 10. SHAFT VOLTAGE MEASUREMENT TEST ‘The shaft voltage was measured between two ends of the shaft during no load running of the motor at rated voltage and frequency. The value of shaft voltage is given in the Table 8. ‘Table 8: Shaft voltage value detaill of Exe HT motors ‘Motor Detail Location Beiween DEw Ew | Between NDEw Eanh | Stall end MORWISSKVAG pole | 64smv. ‘6s Tom STOKWIG.SKV/S pole | SémV SemV 92m 200K W/6,6KV/2 pole | 3S0m¥ 32a Bem Ll, TEMPERATURE RISE / HEAT RUN TEST BY MIXED FREQUENCY ‘The temperature rise was carried out by mixed frequency method. The machine is to be tested was ‘connected as shown in Figure 2 and operated as no load by connecting it to rated voltage and rated frequency power supply. There are reduced voltage having frequency around 35 Hz to 45 Hz shall be ‘supper post at U2, V2, W2 from an auxiliary power source and its voltage shall be gradually raised such that there is flow of rated current in the motor. ‘The phase rotation of the auxiliary power source was chosen so that the direction of rotation when the machine is operated by the auxiliary power source with short circuited stator windings was same as the direction of rotation when the machine was operated by the main power supply. During the test, the following parameters arc measured at a regular interval of 30 minutes: i. Voltage i. Current Power iv. Prequency -y, Winding temperature by RTDs ‘vi. Bearing temperature by BTDs ‘vil, Ambient / Inlet / outlet air Temperature ‘The supplied voltage to Exe motor through terminals (U1, V1 and Wi) fed from alternator Al which is cquivalent to rated voltage of motor and another supply is fed from altemator A? through terminals (U2, V2. and W2) about 20% to 30% of supplied voltage of Al. As soon as the temperature of winding was thermally established i.e. two consecutive temperature readings are within 0.5%C then switched off the supply and stopped the motor within the specified time and measured the bot resistance of stator winding at intervals af 15 seconds by Volt-Ampere method. Figure 2: General layout diagram of ‘mixed frequency test set up eectInternational Journal of Research in Electrical & Electronics Engineering ‘Volume-1, Iseue-1, July-September, 2014, www daster.com (0) 2347-5439 ISSN AP) 2343-0025, ‘The cold resistance of stator winding and motor temperature was measured and recorded. Then motor ‘was run for several hours at full load until thermal stabilization was attained. The loading parameters ‘on motor and temperature of RTDs and other parts of motor as given in Table 9 and Table 10 at every hhalf an hour interval was taken. When the temperatures reading of stator body between two consecutive readings were same then it was confirmed that the motor was thermally stabilized. The ‘motor was then switched off and hot resistance of stator winding was measured within the specified time and accordingly temperature rise of stator winding is calculated. The measurement of temperature afier shutdown by the resistance method requires a quick shut down of the machine at the end of temperature rise test. The specified time delay after switching off power of machine is 120 seconds for 201kW to S000KW rated motor. The same method is applied on al three designed Ex ¢ HT motors for ‘heat run test, ‘Table %: Loading parameters for Exe HT motor ‘Mavor | Prinazy supply Cine wollage) ‘Loading current | Secondary supply Ry [Ys [oR [essen [R B RY [VS [GR | Femesy How _[esoy [asm | asoow | so [ora [ova [ray | iraaw | 1ra0v | aro ne ‘TORN [xnav [esory [srw | soe [248A [248A sen [aseow | rasov | ss sate 9.5 ant [osnov [esosy—[ssnow | sant [trea [ais sa [isssv | ixssw [ ressv [3s amis ‘The RTDs are embedded into slot of stator winding during construction of moter. The value of each RTD is measured after half an hour interval. The temperature of bearings is measured by thermometer method as well as.embedded temperature detector. The dial type thermometer is placed near the outer ring of the bearing. It is ensured that there is:no any air gap between thermometer and outer ring of the bearing, The RTD value is measured in ohm and it needs to convert in *C. ‘The resistance value is converted into °C by using Eq. (1): ‘Resistance in °C =(Mecasured Resistance value of RTD - RTD resistance ) /0:385 o PT 100 is used for all RTDs so RTD is having 100 resistance hence Eq.(1)can be written as, ‘Resistance in °C =(Measured Resistance valuc of RTD - 100) # 0.385 Q ‘The final value of RTD in © is calculated in °C with the help of Eq, (2) and final value of RTDs and ‘other parts of motors are given in °C in Table 10. ‘Table 10: Final temperature in “C after thermal stabilization of 810kW motor ar ale i Winding RTD DE Barag —[ NDE tearing | Moca bay RTD Tab a Tae peso Pe saz [so ans fas moet [as fo EY 70, 2 BREW Pree Pee [ree poe [sop sree [st [set [aa [a2 [er [sa [2 a w si ls 12. LOCKED ROTOR TEST ‘The motor is locked and value of current is increased as 100%, 150% and 200% of rated current of the motor. The rated current is 974, 121A and 217 A for 810KW, 970kW and 2200kW designed Ex © ‘motor respectively. The value of voltage and current is obtained in the lacked rotor testis given in the ‘Table 11 for all three designed motor. 59International Journal of Research in Electrical & Electronics Engineering Issx (00 267-5439 ‘Volume-1, Iseue-1, July-September, 2014, www faster.com «By 2348-0025 ‘Table 11: Locked rotor test on Ex e HT motors. Motor rating Current Vollage with wxpect fo current 100% 150% 200%, 100% 150% 200%, ow aaa | Wea | SRA | TW | 2seW | se o7OKW T2086A | Ieee | 229A [| 17MOV | 2680W | as 200K Tinsa | asa | SSA | Iesov | 2smv 30 13. MOMENTARY OVER LOAD TEST All the motors were tested for over load at 160% of the full load current (FLC) for 15 seconds as per ISMEC 60034-1 to check the overload capability. All the motor withstood overload of 160%FLC for 15 seconds successfully. There was not observed any abnormal behavior on any motor. The test details. is given in Table 12 Table 12: Momentary aver load values of Ex e HT motors Morr Dem [FOC | 10% PLC] Remark S1OEW. WTA [156 A, ‘No abaorinal Behavior observed TIOW TA [1A "No abaoemal behavior observed OK PE WELEY ‘Ne abaormal behavior observed 14. IMPACT TEST ‘One kg mass of hardened ste! was allowed to fall vertically from the height of one meter on the surface of the: enclosure to create high level impact energy for gas Gr. I. Impact test has been conducted successfully as per clause 26.4.2 af IS/IEC 60079-0:2004 on the encosures as shown in Table 13. ‘Table 13: Impact test detail of Ex e motor Ten Height from | Weight dropped | Impact] Remark enclosure _|onenclosure | energy Morar enclosure T meter Tg. | No deformation? damaged observed Fan hoodicover Tmeier he | No deformation? damaged observed Main Terminal Box Tmeier Ts T__| No deformation? ‘damaged observed ‘usiallry Temminal Box Taser The Tl [Ne deformation? for RTDs and BTDs damaged observed ‘Ausiallry Terminal Box T meter Tks 7H [ No deformation / for Space Heater damaged observed ‘Auiallry Terminal Box Tmaier Te | Ne deformation 7 for Neutral damaged observed 15, IMPULSE VOLTAGE TEST ASSESSMENT ‘As per the requirement of standard IS/IEC 60079-72006, impulse generator was set for generating the ‘waveform having rise time between 0.2 p1 secs to.0.5 11 secs and time to half peak value of 20 p secs to 30 p secs. Ten voltage impulses of three times the peak phase voltage of 16.2 kV for a rated line voltage of 6.6 kV were applied on the cach test coil of all three Ex ¢ designed motors rated 810kW,‘International Journal of Research in Electrical & Electronics Engineering ‘Volume-1, Iseue-1, July-September, 2014, www faster.com (0) 2347-5439, ISS AP) 2343-0025, ‘970KW and 2200kW as per clause 6.23.14 of IS/IEC 60079-7-2006. The impulse voltage was applied [phase to phase and separately phase-to-carth for all three motors. The test was done in an explosive gas mixture comprising of 21 5% hydrogen in air. There was no ignition occurred in the explosive test mixture during the testing in any casc when 10 impulse of 16.2kV was applicd. The coil of each ‘motor withstood the ten impulses of desired magnitude successfully. 16. HIGH VOLTAGE TEST ASSESSMENT ‘The High voltage testing and assessment has been done successfully to prove the high voltage withstanding capability of Ex ¢ HT motor winding insulation system of the designed Ex ¢ HT motors. ‘The prototype stator capsule (one complcte stator) was prepared for each motor rated 810kW, 970kW and 2200kW for conducting the high voltage test on it, Then the coil was placed inside the test setup hhox and electrical connections were made to the high voltage equipment. The hydrogen gas was then filled into the box and mixed with air to prepare explosive test mixture. The hydrogen percentage was continuously monitored with the help of intrinsically safe (Ex i) gas detector. When the hydrogen percentage reached the required volume around 21%, the connection was closed and the high voltage test was conducted at recommended voltage level and duration as specified in the standards. The sinusoidal voltages of 10kV r.m.s was applied on each stator capsule winding of all three designed motor for 3 minutes. The voltage was applied between one phase and earth with the other phases earthed. No explosions were observed in the box containing 21% hydrogen gas mixture in air during hhigh voltage testing of all three the motors. The maximum rate of voltage rise was measured ‘.Skv/second. 17. INGRESS PROTECTION (IP) TEST. ‘The ingress protection IPSS is conducted on all three motor enclosures as per IS/IEC 60529: 2001 and IS/IEC6Q034-5:2000. The IPSS test has been conducted successfully as per clause 4.9 of ISMEC '60079-7:2006 on the flowing the item as shown in Table 14, ‘Test for the first characteristics numeral (5) was made as per clause 4 of IS/IECS0034-5:2000 by [putting individual enclosure in the test chamber by maintaining depression 20mbar (2kPa) inside the enclosure. The test chamber was contained taleum powder 2kg/m' of the test chamber volume: The size of talcum powder 60-75pm. The test duration was for this test was 2hours. Test for the second, ‘characteristics numeral (5) was made as per clause 5 of ISMEC60034-5:2000 by spraying water on the motor from all possible directions with a 6.3mm nozzle with a water delivery rate from nozzle was maintained at 12.5 litre/min, The distance between motor and nozzle maintained 3meters. The test duration for water spraying on the motor was three minutes. After the test, enclosure inspected for ingress of water and dust quantity. The amount of water and dust has not entered the enclosures of ‘motors which can interfere with its operation. The same process was followed far all enclosure of all designed Ex e motor. olInternational Journal of Research in Electrical & Electronics Engineering Issx (00 267-5439 ‘Volume-1, Iseue-1, July-September, 2014, www faster.com «By 2348-0025 ‘Table 14: IP test detail of Ex e motor Trem ‘Clause and standard ‘Observation ‘Motor enclosure ‘Clause @ and table 4 of ‘No water had entered inside ISMEC0034-5:2000. enclosure ‘Clause § and table 5 of ‘No dust had accumulated inside ISMIEC0034-5:2000. enclosure ‘Nain Terminal Box ‘Clause @ and table 4 oF ‘No water had entered inside {IS/1EC60034-5:2000. enclosure ‘Clause § and table 5 of ‘No dust had accumulated inside IS/IEC0034-5:2000. enclosure “Ruxiallry Teeminal Hox for | Clause 4 and table 4 of ‘No water had entered inside RTDsand BTS: {IS/1EC60034-5:2000. enclosure ‘Clause § and table 5 of ‘No dust had accumulated inside IS/IEC0034-5:2000, enclosure ‘Ruxtalley Teeminal Hox for | Clause @ and table 4 of ‘No water had entered inside Space Heater {IS/IEC80034-5:2000. enclosure ‘Clause § and table 5 of ‘No dust had accumulated inside ISMEC0024-5:2000. enclosure ‘Aaniallry Terminal Box for | Clause @ and table 4 of ‘No water had entered inside Neutral IS/IEC60034-5:2000 enclosure ‘Clause $ and table 5 of "Ne dust had accumulated inside ISMEC60034-5:2000 enclosure 18. CONCLUSION ‘The successful testing reveals that the designed Ex © HT motors rated 810kW., 970kW and 2200kW are fulfilling: the test requirements of relevant standards and these motars are suitable to use in the hhazandous area without producing any arc, spark and excessive temperature which can become source for ignition. The motors arc qualified for temperature class T3 because the temperature rise is not ‘crossed the limit 130°C in heat run test. The performance of the designed Exe HT motor has achieved the requirement of the end user. ACKNOWLEDGEMENT ‘The authors are grateful to Dr. A. Sinha, Director, CSIR-CIMFR, Dhanbad for his kind permission to publish this technical research paper and also wish to record thanks to the Dr. A. K. Singh, Head of Flame & Explosion Lab., CIMFR, Mr. S. R. Prasad, Executive Director, BHEL. Mr. G. P. Baghcl, ‘Deputy General Manager, Mr. N. Khare, Deputy General Manager, BHEL, Mr. B. Jena, Deputy ‘Manager, BHEL, Bhopal for providing necessary help in carrying out this research work. REFERENCES [1], ISMIEC 60529 (2001). Degree of protection peovided by enclosure (IP CODE). Bureau of Indian Standards Is). {2}, ISMIEC 6007-0 (2004). Electrical apparatus for explosive gas atmospheres-General requirements. Bureau of Indian Standards (BIS). 1B) ISMEC 60079-72006). Electrical apparatus for explosive gas atmospheres Increased safety. Bureau of Indian Standards (BIS). |i] ISMIEC 60034-S (2000), Rotating Electrical machines Part S- Degree of protection provided by the integral design of rotating electrical machines (IP cod). Classification, Bureau of Indian Standard. [5] ISMEC 60034-1 (2004), Rotating electrics machines — Part 1: Rating and perfurmance, Bureau of Indian Standards (BIS).