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Design criteria for VSD application motors in Steel Plant

Subrata Biswas & Subhajit Basak


Ex-Marathon Electric Motors (I) Ltd., Kolkata

A Steel plant can be of various types & capacities. Whereas a large steel plant produces finished steel
products from iron ore, there are mini steel plants primarily for re-rolling, forging & other applications,
which convert semi-finished to finish products. A large steel plant require motors for various capacities
& applications like Pump, Compressor, Blower, Conveyor, Mill etc. In many applications like Blower,
Conveyor, Mill etc., AC slip ring motors was the first choice because of its advantage of controlling its
torque & speed as per requirement. For large Mills, DC slip ring motors is also a preferred choice for
its unique torque and speed control & speed reversal advantage. However, there are also some major
disadvantages of AC slip ring & DC motors, some of which is mentioned below:

1. Higher losses in rotor circuit & having lower Efficiency


2. Higher maintenance cost in commutator/carbon brush or slip ring/carbon brush assembly
3. Frequent failure of rotor winding

General purpose motors have been around for many years. But, an inverter duty motor is a much newer
concept that became necessary as motors began to be driven by VFDs (Inverters or, AC Drives). With
the advent of higher rating power electronic devices such as GTO, IEGT, IGBT in PWM inverters,
features of DC drives can be met, if an AC machine is operated with VFD. An AC drive system has the
advantage of rugged construction, higher efficiency, and reduced maintenance. The VFD can be used to
control the speed of the drive motor depending upon the loading, thus saving considerable amount of
energy. The use of ID, FD, PA, SA, de-duster and exhaust fans in such industries, if operated with
VFD, give double advantage. Firstly, the speed of the fan can be controlled without a damper, thus
saving on energy & secondly, the initial cost of the AC machine gets reduced because locked rotor
withstand time limitation becomes invalid. Pump is another application, where reduced output
requirement can be met by running the motor at lower RPM, operated through a VFD. Pump & Fan are
applications, where load follow a Square Torque variation. VFD motors are also extensively used now-
a-days for Constant Torque load applications - like Ball Mill, Conveyor, Crusher etc.

However, the non-sinusoidal variable frequency output of PWM drives has several effects including
increased motor losses, inadequate ventilation at lower speeds, increased dielectric stresses on motor
winding, magnetic noise and shaft current. These effects can combine to damage motor insulation and
severely shorten its useful operating life. It is possible to take proper measure of all irregularities
generated by a VSD on motors by suitably designing it. Hence, despite many advantages of a VSD
application AC motor, a through application check is absolutely necessary for the selection of a motor.
User must send complete specification of driven load to the motor vendor for its evaluation by their
Design office. In this paper we shall discuss the design criteria of such special application motors.

1. Insulation system

Electronic adjustable speed drives, known as variable frequency drives (VFD) used is generally
marketed as Usable with any standard motor. An induction motors insulation system is designed to
operate continuously on a somewhat purely sinusoidal voltage source. However, premature failures of
motor insulation systems begin to occur as fast switching pulse-width-modulated (PWM) VFDs were
introduced. The switching rates of modern power semiconductors can lead to voltage overshoots.
These voltage spikes can rapidly damage a motors insulation system, resulting premature failure.
VFD-induced motor insulation break-down is the result of an interaction between the voltage pulses that
the VFD applies to the stator coils of the motor. Hence, a special insulation system is essential for VSD
application motors, because of the reasons explained below:
Fig 1.

A variable frequency drive operates on the technique of Pulse Width Modulation(PWM), which
attempts to simulate a sine wave by firing many voltage pulses in rapid succession. To get higher
modulation frequency, each pulse may be very short, for e.g, a typical pulse goes from 0 to 600 V DC
in one-millionth of a second. Quite a few variables pertaining to such pulses are of utmost importance
regarding motors insulation.

The peak voltage determines the maximum stress imposed on the insulation during a cycle.
The rise time of the pulse, generally taken as the time for the pulse to attain 10% to 90% of its
peak value, is another parameter which stresses the insulation system. A rise time lesser than
0.1s is considered to be a dangerously steep fronted waveform and causes pin holes in motor
winding insulation.
The dv/dt value of the steep fronted waveform is the final parameter that seriously stresses the
motors insulation system. A high value of change in applied voltage in a very small change in
time is thus detrimental and should not repeatedly exceed the basic Impulse Level of the
interturn insulation used.

Thus, to select an insulation scheme to be used in a motor in conjunction with a VFD, the peak voltage
withstand level may be selected by the formula:

Vp = (Voltage tolerance) x (peak-to-peak Voltage overshoot)

where, Peak-to-peak Voltage overshoot = x r.m.s. Line Voltage x 2 = 2.83 x r.m.s. Line Voltage
Voltage tolerance = 1.1

Preventive measures can be taken to avoid motor failure caused by voltage spikes. Inverter-duty motors
are wound with voltage spike-resistant insulation system. Smaller rated motors use inverter-grade
magnet wire(special varnish with thick coating) to protect the adverse effects of voltage waveforms
produced by VFDs. Large motors use Glass or, Polyester tape covered rectangular conductor to protect
motors from inter-turn failure. Ground insulation for all motors is also designed to withstand higher
voltage. NEMA MG 1-2011, Part31 specifies that insulation system for low voltage(<= 600V) inverter
duty motors should be designed to withstand an upper limit of 3.1 times motors rated line to line
voltage. This is equivalent to an upper limit of 1370V peak at motor terminals for a motor rated 440V.

2. Introduction of Harmonics : Overheating problem and Pulsating Torque

For the AC power system, which includes the inverter and the induction motor, is a non linear load
whose current and voltage waveforms include harmonics (Fig 2). The characteristic harmonics
generally produced by the rectifier are considered to be of the order h=np1(n is an integer, p=pulses of
the inverter) on the AC side i.e. on the power line. Thus for a 6-pulse inverter, 5th and 7th order
harmonics and for a 12-pulse inverter, 11th and 13th order are very much pronounced and are quite
harmful. The frequencies of these harmonics would be 250 Hz, 350 Hz, 550 Hz, and 650 Hz for a 50Hz
sinusoidal AC supply. The other higher order harmonics for n=2,3 and above, the magnitude reduces
and even though they may be present, their effects are not so detrimental and can be overlooked.

Devices connected to an input AC line with these harmonics will act as if they are connected to a 50 Hz
line with the actual line voltage, plus the harmonic frequencies with voltages associated with the
magnitudes of the harmonics. The actual waveform will appear on an oscilloscope as a single, distorted
wave. Fig 3. shows a badly distorted (18% THD) voltage waveform with the following harmonic
content: 5th harmonic (15%); 7th harmonic (6%); 11th harmonic (6%); 13th Harmonic (4%).

Fig 2. Fig 3.

Motor Drive harmonics can also result in torque ripples (alternating torque occurring at various
frequencies, depending on the type of drive system) being generated by the motor that can affect the
performance of the driven load (Fig 4).

Fig. 4

The percentage of current harmonics in a system is dependent mainly upon the following factors for a
PWM VFD:
1. The reactive impedance (XL) of the power source feeding the drive, including the transformer,
cables or busway, and any added reactance.
2. The number of pulses in the AC to DC converter sections of the VFD (as seen by the power
source).
3. The full-load current of the source transformer feeding the VFD's branch circuit.
Few measures that can reduce VFD harmonics are:

1. Using large DC or AC choke


2. Using higher pulse rectifiers i.e. 12, 18 or 24-pulse instead of the conventional 6-pulse variants
3. Using an active IGBT rectifier
4. Using external active filter

In reality, it has been observed that there is some additional temperature rise of motor winding when run
with VSD system, compared to run of the motor without VSD. Hence, it is safer & advisable to use
some deration of motor output when run with VSD system.

3. Forced Cooling arrangement

(a) Variable (T-S) curve : Pump, Blower, Fan, Centrifugal Compressor etc. are examples of variable
torque load, where torque varies as square of load & power output demand various as cube of speed
(Fig 5). Since, the power demand varies with the cube of speed, hence during the most common
(10-100)% speed variation for such kind of application, although motor cooling reduces at lower speed,
but motor power demand also reduces as the cube of speed. There could also be type of load having
linear variable (T-S) curve, where power varies with square of speed (Fig 6). Since, power demand
reduces considerably for both linear & square law (T-S) load curve, therefore motor does not generally
require separate forced cooling arrangement for operation at reduced speed.

Fig 5. Squared torque variation Fig 6. Linear torque variation

(b) Constant (T-S) curve : Conveyor, Crusher, Mill etc. are examples of constant Torque vs. Speed
load curve. Here, power demand reduces linearly with speed & hence motor cooling is greatly affected,
while run at reduced speed (Fig 7). From the electrical point-of view, it is quite feasible to achieve any
speed below the base speed for a constant torque application by suitably keeping the V/f i.e. air gap flux
constant, to prevent overheating of the motor core. But from mechanical construction point of view, it
is important to note that during reduced speed operation, the speed of the shaft mounted fans get
reduced, which reduces the volume of cooling air in cubic relation to the fan speed. Thus the natural
cooling system of the induction motor becomes inefficient. In view of this, for constant torque load
application, a forced cooling arrangement is generally preferred over shaft mounted fan cooling, as the
cooling is independent of motor speed.
Fig 7. Constant torque load

Forced cooling arrangement may be basically of two types depending on the type of motor. For motors
with single cooling circuit, like TEFC, instead of shaft mounted fan, separate motor driven fan is used.
Interlocking arrangement is provided in motor control panel, so that motor does not start unless
separately excited fan is run first. Picture of such kind of cooling arrangement is shown in the
following photographs (Fig 8(a) & Fig 8(b) ).

Fig 8.(a) Single circuit forced cool motor Fig 8.(b) Forced cooling unit

Large motors with CACA & TETV enclosure are having two fans for internal & external cooling
circuits. For VSD application of such motors, forced cooling arrangement has to be done for both the
cooling circuits. Two separately excited motors drive the fans for internal & external air cooling circuit.
Following pictures demonstrate the forced cooling arrangement of internal & external cooling circuits
of motor. (Fig 9(a) & Fig 9(b)).

(a) Forced cooling for internal air circuit (b) Forced cooling for external air circuit

Fig 9. Double circuit forced cool motor

4. Bearing current and their protection


In Electrical machines, any unbalance in magnetic circuits, or in the electrical phase currents that
encircle a shaft, can create flux linkages with the rotating system. When the shaft rotates, these linkages
can produce an electrical potential difference between shaft ends. This voltage is capable of driving a
circulating current in a shaft-to-frame loop by using two bearings to complete the circuit.

Further, due to the high-speed switching frequencies used in PWM inverters, all variable frequency
drives induce shaft voltage in AC motors. The switching frequencies of insulated-gate bipolar
transistors (IGBT) used in these drives produce voltages on the motor shaft during normal operation
through electromagnetic induction. This voltage is capable of driving a circulating current in a shaft-to-
frame loop by using two bearings to complete the circuit. Once these voltages reach a level sufficient to
overcome the dielectric properties of the grease and oil film in the bearings, they discharge along the
path of least resistance typically, the motor bearings to motor housing.

During virtually every VFD cycle, induced shaft voltage discharges from the motor shaft to the frame
via the bearings, leaving a small fusion in the bearing race. These discharges are so frequent that soon
the entire bearing race becomes marked with countless pits known as frosting (Fig 10(b)). Due to
continuous operation, the frosting increases, eventually leading to noisy bearings and bearing failure. A
phenomenon known as fluting (Fig 10 (b)) may occur as well, producing washboard-like ridges across
the frosted bearing race. Fluting can cause excessive noise and vibration. Regardless of the type of
bearing or race damage that occurs, the resulting motor failure often causes high costs in downtime and
loss of production. Failure rates vary widely depending on many factors, but evidence suggests that a
significant portion of failures occur within 3 to 12 months after system start-up and electrical damage
has become the most common cause of bearing failure in AC motors with VFDs. If half of all AC
motor failures are due to bearing failure, almost 80% of these are caused by electrical damage to
bearings.

To eliminate the induced shaft current, the basic requirement is to insulate the NDE bearing (in case of
single drive end) or both the bearings (in case of double drive end) from the conducting loop. If the
opposite drive end bearing(or both bearings) is/are isolated from the frame, the conducting path is
impeded by the insulation, and the circulating shaft current in that machine is inhabited.

Various methods are being used by motor manufacturers to mitigate such shaft currents. However, the
most common practice is to provide insulation on NDE bracket (Fig 11(b)) to disconnect the circulating
current path between the two bearings. Alternately, insulated bearings (Fig 11 (a)) can be used. The
shaft voltage is grounded by providing a connection of shaft to motor housing via Brush Holder/Carbon
Brush arrangement (Fig 11(c)).

(a) Fluting (b) Frosting

Fig 10. Damaged Bearing race


Fig 11.(a) Insulated Bearing Fig 11.(b) Insulated Bracket Fig 11.(c) Earthing Brush

5. Rotor design

Motors with VSD application usually operate at (10-100)% speed. It is always intended to design a
rigid rotor shaft construction for VSD application motor, so that its critical speed is beyond the
synchronous speed. Usually the 1st critical of VSD application motors are designed at least 20% above
synchronous speed. Large rated high speed rotors (2 Pole), when used with oil lubricated sleeve
bearings are generally designed with flexible rotor and has limitation on its performance with VSD
operation.

Three approaches (or any combination thereof) may be considered for dealing with lateral or torsional
critical speeds that fall within the speed range of the motor and load system:

1. Modify the design of the system to place the critical speeds outside the operating speed range
2. Practice critical speed avoidance by changing the operating speed range
3. Allow short-term operation near critical speeds with sufficient damping

6. Speed sensor

VSD application motors are designed to perform at required speed. Hence, a closed loop speed system
is designed & same is fed to VSD for its performance. Generally, an Encoder (Fig 12) is mounted at
non-drive shaft end of motor to monitor the speed of operation & feed same to drive control system to
adjust its torque. Hence, in motor design, provision for Encoder at non-drive end shaft has to be
provided in general for VSD application motors.

Fig 12. Encoder fitting

7. Cable length : Mitigating resonance

Although it is not directly related with motor design, but design of the connecting cable and its length to
motor is also of primary importance for VSD application. Improper cable use may lead to premature
motor failure.
Drives and motors often need to be separated by distance. Motors in wells must be controlled from
above ground - the deeper the well, the longer the leads between the drive and the motor. In some
plants, motors can withstand the harsh surroundings (Dust, Smoke etc.). However, sensitive VFD
electronics cannot tolerate such environments, forcing long distances between the motor control centres
that house the Drives and the motors that they control. Conveyors and Presses often utilize single Drive
to operate multiple motors that are positioned along the length of the conveyor. The length of the
conveyor system often dictates the longest distance between a Drive and motor.

Electrical energy flowing in the cable contain high frequencies. If this radio frequency energy is
not contained within the cable, it can radiate out to interfere with the proper operation of nearby
electronic equipment, commercial-grade Ethernet systems, simple instrumentation wires and
circuits that have absolutely nothing to do with the VFD system itself. This noise emission can
sometimes be very difficult to track down and eliminate and is likely the single most significant
problem associated with VFD systems today.

Unless a proper cable shielding design is used to control it, noise emission from a Drive system
cable can disrupt other plant machineries and factory operations. Hence, properly shielded cable
is recommended for use with VSD application motors. Moreover, because a longer cable
radiates more noise, the length of cable runs must be limited.

There is another potentially serious concern with use of VFDs. With an improperly selected
cable length, voltage waves reflected back from the motor toward the VFD along the cable can
produce excessively high voltages in the cable's conductors, as they add to the voltage that is
already there. Voltage wave reflection is a function of the voltage rise time, dv/dt, and the
length of the motor cables which behave as a transmission line. Because of the impedance
mismatch at both ends of the cable(cable-to-inverter and cable-to-motor), some portion of the
waveform high frequency leading edge is reflected back in the direction from which it arrived.
As these reflected leading edges encounter other waveform leading edges, their values add,
causing voltage overshoots. Peak voltages of up to 2.5 times the nominal system voltage are
sometimes present in the cable, resulting a number of in-service motor failures. There is also
some concern over possible long-term cable damage under high voltage - especially with VFDs
operating at 575 volts and above.

Most manufacturers of VFDs publish a maximum recommended distance between their equipment and
the motor. Maximum tolerable distances vary by manufacturer, but might be 100 to 250 feet. It is
advisable for the users to follow the restriction of maximum distance, as otherwise there may be
premature motor winding failure.

Conclusion

In summary, it can be concluded that general purpose AC & DC motors can be run with Drives in many
applications. However, inverter duty motors are designed to operate at much lower speeds without
overheating and they are capable of withstanding higher voltage spikes without their insulation failing.
VFD application motors are fast becoming popular for better performance and savings in energy cost.
With the increase in performance, there is an increase in initial cost. However, the additional cost can
be worth, if you need greater performance. It is also worth mentioning that with continuous
advancement in power electronics, cost of Electric Drive has come down & the difference in cost of an
inverter duty motor is also nominal compared to a general purpose motor. Thus, with additional initial
cost, greater performance is available for VSD driven motor application and that is why the use of VSD
application motors is increasing day by day.
Acknowledgement

We are very much thankful to the management of Marathon Electric Motors(I) Ltd. for their key input
as our technical experiences and photographs, which have been used in this paper for various
illustrations.

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