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EE4092: Laboratory practice VII

TEMPERATURE RISE OF AN
ELECTRICAL MACHINE









Instructed by: Dr. Udayanga Hemapala
Group members:
100116L Ekanayake E.M.H.A.
100255K Kirinde W.M.C.N.S.
100342B Munasinghe D.T.
100627E Muthuransi L.W.N.
Name : S.B.N.S.Senanayake
Index No : 100494P
Group : G-11
Field : Electrical Engineering
Date of performance : 20.08.2014
Date of submission : 03.09.2014

OBSERVATION SHEET
NAME : S.B.N.S.Senanayake
INDEX NO : 100494P
PRACTICAL : Temperature Rise of an Electrical Machine
GROUP NO : G11
DATE OF PER. : 20/08/2014
INSTRUCTED BY : Dr. Udayanga Hemapala


- Rated Current of the motor : 2.8A


















Time (minutes) Winding resistance ( )
0 7.1
5 7.9
10 8.2
15 8.4
20 8.6
25 8.6
30 8.6

THEORY
a) Temperature rise
The relationship between resistance and temperature can be denoted by,

) 1 (
1 0 1
ou + = R R
-------------(1)
Where, R
1
is the winding resistance at ambient temperature of
1
u

R
0
is the winding resistance at 0
0
C
is the temperature coefficient of resistance for copper
Similarly for R
2
resistance at
2
u

) 1 (
2 0 2
ou + = R R
---------------(2)

(1)/(2) and using the graph,

) 235 (
) 235 (
) 1 (
) 1 (
1
2
1
2
1
2
u
u
ou
ou
+
+
=
+
+
=
R
R


1 2 1 2
) 235 ( ) 235 ( R R u u + = +


235 ) 235 (
1
2
1 2
+ =
R
R
u u
------(3)
b) Temperature rise Vs time curve
Consider about small time interval t and temperature rise at that time interval is then
Heat produce = p(t)
Heat dissipated = hA(t) (from Newtons law of cooling)
Heat Stored from temperature rise = mc()
Where, h is the heat transfer coefficient
A is area
m is mass
c is specific heat capacity
From law of energy conservation,
Heat produce = Heat dissipated + Heat Stored from temperature rise
p(t) = hA(t) + mc()
take lim
(t) = 0
p(dt) = hA(dt) + mc(d)



When t tends to infinity, will approach to a constant value

and therefore,


Define time constant


Multiply the equation by integrating factor


By integrating the equation,
(

Where C is a constant


By substituting the initial conditions, t = 0,

,where

is the initial temperature


rise of the motor

----------(4)

c) Estimation of Thermal Time Constant (t)
By differentiation equation (4) with respect to time, at t = 0,
0
) (
=

=
t
o m
dt
du
u u
t

For the machine started at the ambient temperature



Therefore,

0
) (
=
=
t
m
dt
du
u
t






CALCULATIONS

Sample calculation:
When Time = 5 min,
Winding Resistance (R
2
) = 7.9
Ambient temperature (t
1
)

= 30
0
C
Winding Resistance at ambient temperature (R
1
) =7.1
Using equation (3), 235 ) 235 (
1
2
1 2
+ =
R
R
u u
235
1 . 7
9 . 7
) 30 235 (
2
+ = u

u
2
= 59.9
0
C
Temperature rise = u
2
- u
1
= 59.9-30 = 29.9
0
C













Finding
m
u and t from the graph;

m
= 56
0
C
mi C
dt
d
t
/ 6
5 . 2
15
) (
0
0
= =
=
u


0
) (
=
=
t
m
dt
du
u
t
=

= 9.33 min


Time (min)
Winding resistance
( )
Temperature (C)
Temperature rise
(C)
0 7.1 30.0 0.0
5 7.9 59.9 29.9
10 8.2 71.1 41.1
15 8.4 78.5 48.5
20 8.6 86.0 56.0
25 8.6 86.0 56.0
30 8.6 86.0 56.0

GRAPHS
b) Temperature rise Vs time curve












Table 1: Temperature Rise Vs Time










Time (min)
Temperature rise
(C)
0 0.0
5 29.9
10 41.1
15 48.5
20 56.0
25 56.0
30 56.0


0
5
10
15
20
25
30
35
40
45
50
55
60
0 5 10 15 20 25 30 35
T
e
m
p
e
r
a
t
u
r
e

r
i
s
e

(

C
)

Time(minutes)
Temperature rise Vs Time

DISCUSSION

1. The various methods of measuring the temperature rise of the windings.
The temperature rise is defined as the average temperature rise of the windings above
the ambient temperature.
The temperatures of windings can be determined by various methods.
- The change of resistance method
Resistance of the winding increases with the temperature of the winding. Therefore measuring
winding resistance can be used as a method for measuring temperature of the winding.
Winding temperature can be calculated using the following equation.
235 ) 235 (
1
2
1 2
+ =
R
R
u u
Where,
R
1
= Winding resistance at ambient temperature
R
2
= Winding temperature after the operation of T time

1
= Ambient temperature

2
= Winding temperature after the operation of T time

- Using Temperature sensors
In this method temperature sensors are inserted in to the winding core and in between the
windings of the machine. Thermocouples and resistance temperature detectors are most
commonly used sensors and among those two thermocouples are used most frequently.
When using thermocouples, it is important to attach the thermocouple tightly to the
device. Gluing or soldering the thermocouple is the recommended attaching method. In
this method approximate temperature of the winding can be directly measured.

- Stator current method
In this method, the stator current is used to predict the winding temperature. A point on
the motor thermal damage curve which is provided by the manufacture represents a
thermal time limit. Thermal time limit gives the idea of how long a motor can withstand
the corresponding level of stator current without exceeding the thermal boundary
specified by the motor manufacturer.




- Optical method (Infrared thermography method)
Figure 1: Infrared Thermography method
Thermal imager is a non-contact temperature measurement technique.IR cameras are
often used to get a quick view to locate the hotspots. The temperature at each point can be
identified by the different colors of the thermal image. The accuracy will be poor, due to
the different emissivity of different components. Also this method only provides the
facility to read the temperature on the outer surface of the machines. Therefore this
method can only be used to take the approximate value of temperature is sufficient.

2. The importance of the class of insulation

Insulation material characteristics undergo heavy changes when the temperature varies.
Use of high temperatures than the recommended values generally reduces the lifetime of
the electrical insulating materials. So an upper temperature limit is set for insulation to
operate reliably over long duration.
Electrical insulation materials are categorized into certain basic thermal classes which
show the maximum temperature in degrees of Celsius which should be used for that
insulation material. Excess temperature to the insulation will result in premature failure
due to reduced winding life.
Insulation classes are rated by standard NEMA (National Electrical
Manufacturers Association) classifications according to maximum allowable operating
temperatures as shown in figure 2. Allowable temperature rises are based upon a
reference ambient temperature of 40
o
C.






Figure 2; NEMA Insulation Classes
A motor should not operate with temperatures above the maximum.
Each 10
o
C rise above the rating reduces the motor lifetime by one half as shown in figure
3.


Figure 3: Variation of Lifetime of motor with Temperature

3. Comparison of the obtained results with the machine ratings
The insulation class of the three phase induction motor which was used for the
practical is Class F. According to the NEMA insulation classes the maximum allowable
operation temperature of the machine is 155
0
C and allowable temperature rise is 105
0
C
when ambient temperature is 40
o
C. In our practical the maximum temperature rise
obtained was 56
0
C. The maximum operating temperature was 86
0
C and we assumed that
the laboratory operating environment is at ambient temperature of 30
o
C.
Those obtained values are well below the maximum allowable limits specified by
the NEMA insulation classes. Therefore the motor operates safely in the laboratory
environment.



4. The necessary to know about the parameters estimated in this experiment
- Maximum temperature rise
The maximum temperature rise gives maximum temperature difference with
respect to its ambient temperature when the machine is continuously operating. The
temperature of both windings and the core rises due to copper loss and hysteresis loss.
This temperature rise of the windings is directly affected to winding insulation. If it
exceeds the nominal value, final insulation failure may also happen. Therefore it is
important to know the final machine temperature. Due to the condition of the installed
environment of the motor Ex: enclosures, cooling mechanism, the final temperature rise
can be changed than the deigned values. Also it is important to the maximum temperature
rise, when designing nearby other equipment and the enclosure boxes because they
should be able to withstand this temperature.
- Thermal time constant
This is the measure of the rate of change of the temperature of the motor. This is a
measure of both thermal mass and thermal resistance of the machine. It gives information
regarding how motor is affected by heat. Thermal time constant become very important
parameter, when motor running in overload condition for long time.

5. The various methods of cooling general purpose machines

- Natural cooling
This method is used in small machines. Heat is transferred to the atmosphere by
natural convection and this process is accelerated by wind.
- Forced air cooling
In this method air is circulated internally and externally by one or more bi-
directional type fans mounted on the rotor shaft. In addition, the external frames of the
motor are usually provided with cooling ribs to increase the surface area for heat
radiation.
- Direct cooling
In this method, cooling ducts are formed through the stator core of the machine.
In medium size synchronous generators, water is normally used as a cooling medium and
the water is pumped though stainless steel cooling tubes. Air or H
2
gas is used as cooling
medium, in large electric machines which are operated at higher power ratings.

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