LIFE OF ELECTRICAL MACHINERY AS AFFECTED BY TEMPERATURE.

A TECHNICAL PAPER

PRESENTED BY

ENGR. NGANG B. NGANG, MNSE.MIEEE

DURING THE ENGINEERING WEEK

ORGANISED BY

THE NIGERIAN SOCIETY OF ENGINEERS, EKET BRANCH.

VENUE:

DATE: 22ND JUNE,2014

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ABSTRACT

This paper explained the effect of ambient temperature size and rating of a machine.
It illustrates practical calculations needed to estimate the life reduction factor and
reduced life expectancy of a given electrical machine. The paper explains the limiting
temperatures of insulating materials and their classification. Explanation of machine
name plate information is highlighted. Mathematical derivation of temperature rise  of
an electrical machine is performed from the exponential heating characteristics. The
paper describes the best way to operate an electrical machine example an electric motor
of large horse power rating. All devices that use electricity give off waste as a byproduct
of their operation. Transformers are no exception. Heat generated in transformer
operation causes temperature rise in the internal structures of the transformer. In general,
more efficient transformers tend to have lower temperature rise, while less efficient units
tend to have higher temperature rise. Transformer temperature rise is defined as the
average temperature rise of the windings above the ambient (surrounding) temperature,
when the transformer is loaded at its name plate rating.

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 1. INTRODUCTION
2.
Temperature plays an important part in the efficient operation of a machine. The life of
any machine is seriously shortened by overheating. Consequently, the operating
temperature of any machine affects its life expectancy, along with a number of factors
affecting the machine rating. The type of service to which a machine is subjected also
affects its life. The type of insulation used in the windings of any machine does not only
affect the allowable temperature rise but also the life expectancy of the electric machine.

2. FACTORS AFFECTING MACHINE RATINGS

Several factors affect machine ratings; electric machines are rated in terms of their
output capacities. Generators are rated in terms of their output KW or KVA capacity at
given rate prime mover speed and a rated terminal voltage. Motors (DC and AC) are
rated in terms of output capacity in shaft horsepower at rated speed, full load current and
applied voltage. When the electric machine is operated under this name plate conditions,
the implication is that the temperature rise will not be excessive and that the machines
will not overheat. The consumer who for reasons of economy, purchase a 10 HP motor to
drive a 12 or 15 HP load continuous, runs the risk of caveat emptor in purchasing a
product that:
1. Will deliver rated speed at rated load but not rated speed at an over load
2. Will overheat badly and have shorter life.
3. Will operate at a somewhat lower efficiency at the overload for the duration of its life.

All electric machines nameplate provide certain information that bears on machine rating.

3. NAME PLATE INFORMATION

We shall base our presentation on electric motor, which is a rotating machine, not all
motors show all of the possible information that can be shown on a nameplate.
Any of the following items may appear on a motor nameplate.
1. Motor type
2. Frame size
3. Enclosure
4. No. Of phases orDC
5. Horsepower out put
6. Frequency
7 Rated speed
8. Voltage rating.
9. Current rating
10 Allowable temperatures rise above ambient.
11. Duty cycle
12 Winding insulation class letter

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 13 Design class letter
14. Locked- rotor code letter
15. Thermal protection
16. Service factor
17. Manufacturers identification numbers.
18. Manufacturers model number

4. TEMPERATURE RISE AND AMBIENT TEMPERATURE STANDARD

The standard allowable temperature for electric dynamos is currently set at 40deg. C.
This is the maximum limiting starting temperature at which all heating begins as a
result of electrical loading. All machinery insulation is tested on the basis of a
temperature rise above 40deg.C. A motor operating in a confine area next to high
temperature device (hydrocarbon gas flare burner/boiler) may experience an ambient
temperature of 60c. This 20deg.C difference is allowable and does not materially
affect the expected life of the motor. Motors rated on the basis of a 40c ambient
temperature should be capable of continuous operation at rated load without
excessive damage to the insulation.
The following conditions when observed can improve the efficiency of the motor:
1. The ambient temperature does not exceed 40 deg. C
The altitude does not exceed 1km
2. The atmospheric conditions (dust, moisture)

5.1 ANALYTICAL APPROACH TO EVALUATE THE LIFE OF ELECTRICAL

MACHINERY AS AFFECTED BY TEMPERATURE

Consider the temperature rise in a machine say an electric motor, the losses in a motor
are converted into heat. The heat thus produced will increase the temperature of the
various parts of the motor. The increase in temperature is dependent on the following
factors:
1. Amount of heat produced.
2. The amount of heat dissipated from the surface of the motor.
3. The rate of rise in temperature will be high in the beginning but will decrease
gradually with time and finally the temperature of the motor attains a steady value. At
this point, the heat produced and dissipated will be equal.
The following assumptions are made for calculating the temperature rise:
1. The losses (heat produced) remain constant.
2. The heat dissipated is directly proportional to the difference in temperature of the
motors and the cooling medium.
3. Temperature of the cooling medium remains unchanged.

Let
W = the power converted into heat in watts or joules/s
M = mass of the active parts of the motor in kg.
S =Specific heat of the materials in joules/kg
A =cooling surface area in sq.m

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  =rise in temperature in deg.C
f =final steady temperature rise in deg.C
=Coefficient of cooling in joules/sec/unit surface area (m2) between machine
surface temperature and ambient cooling temperature.
Now, consider a motor whose temperature has increased by deg.C in time t seconds.
If this motor continues working for a further small period say dt sec. Then its
temperature is increased by a small amount say d deg.C
1. The rate at which the heat is absorbed by the motor =MSd/dt joules/sec……….1
2. Rate at which the heat is dissipated=A ……………………………………… .2
3. Rate at which energy is converted into heat in dt seconds =W joules/sec…………3
4. Rate at which the energy is converted into heat =rate at which heat absorbed +rate
at which the heat is dissipated. ……………………………………………..4
Inview of equ. I and 2, equation 4 can be written as W=MSd/dt +A J/sec…. 5
Or W-A = MSd/dt…………………………………………………………..6

dt= MSdƟ……………………………………………………………………….7
W-AƟ

Integrating equation 7 we have dt = MSd

1 d W-A
dt = MS W-A

These give t as –MS Loge(W-A) +K1……………….8

A

Where k1 =MS/ALoge
In view of equation 8 and 10, t = -MS/A log e(W-A) +MS/A(loge)

= -MS (loge(W-A) –logeW)

A

-MS (loge-A) …………………………………………EQU.11

A W

Equation 11 can be written as -A T =loge (1 - A) ………EQU. 12

MS W..

-At…………………………………………………………………
OR 1-(A) =e MS
W

 =W (1-e-A t)……………………………………………13
A

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The final steady temperature is obtained when time is infinity, thus equation 14 for final
steady temperature can be written as f =W/A(1-e-A&/MS) = W/A……..15

Inview of equation 14 and 15

 =f(1-e-At/ms) …………16

Re-writing equ. 17 inview of equ. 16 , =f(1-e-t/T) ………………………………………..18

-t/T
COOLING =e …………………………FOR COOLING OF MOTORS

RECALL THAT for every 10 degree Celsius of continuous operation over the recommended
hottest-spot temperature limit, the winding life is cut in half. Let us assume that the
average motor life of 40 deg.c ambient temperature motor operating continuously within
its maximum limiting temperature is 10 years. One can predict the reduction (R) in life
for motors exceeding the temperature limit and the extension (E) of life for motors
operating well below the temperatureslimit. The empirical exponential relation to enable
the calculation of either the extension or reduction of life of a 40 deg.ambient
temperature motor is stated below:

E/R factor=2(10deg.c) unitless relation....................*A

Where E= extension of life

R= reduction of life

=positive temperature difference between the maximum hottest-spot temperature of its

insulation (see table) and the actual temperature recorded by embedded hot-spot detectors
in its winding (RTD).

EXAMPLE 1.

Given that a motor using class A insulation is continuously operated for 6 hours at rated
load at an elevated ambient temperature such that its embedded detectors record a
temperature of say 125deg.c Calculate the life reduction factor and reduced life
expectancy of the motor. (Assume a standard life ofv10 years).

SOLUTION: R = 2(10deg.c)

= 220/10deg.c =22 =4

Life calculated =Life original =10/4 =2.5year

Example 2: For the same squirrel cage motor, when its detectors continuously record a
maximum hot-spot temperature of 75deg.c. Calculate the life extension factor and
increased life expectancy of the motor.

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SOLUTION: E =2T/10DEG.C =2(105-75deg.c)/10deg.c =230/10 23 = 8

Life calculated = life original x E = 10 yearsx8 = 80 years.

6. CONCLUSION

As a result of this analysis, motors are rated according to the work they perform

The basic types of rating are:

1. Continuous duty,

2. Short time duty

3.intrmittent duty

All insulating materials employed in electric machines are divided into the following
seven classes:

1. class 0 insulation 90deg.c

2. class A insulation 105deg.c

3. class B insulation 130deg.c

4. Class F insulation 155deg.c

5. Class H insulation 180deg.c

6. Class N insulation 200deg.c

7. Class r insulation 220deg.c.

The limiting temperature should never be exceeded in service because it will result in
deterioration and break down of the insulation. Consequently, the life of the motor will be
shortened.

REFERENCES:

1.IRVING, L. K, Electrical machinery and transformers, second edition,1991.

2. SAY, M. G. Alternating current machines, fourth edition, 1978.

3. BALBIR, SINGH Electrical machines design ,1982

4. ALAN, S. Electrical power and measurement, 1980.

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5. IBE, A. power system engineering, 2002.