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Medium and High Voltage Three Phase Induction Motors

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Three Phase Induction Motors Medium and High Voltage

In conjunction with a world renown consultant company, WEG developed its three phase induction motors which allow easy maintenance and high performance level. Divided in two different lines, M Line and H Line, the WEG three phase induction motors became the best solution for those applications requiring such motors. Due to its mechanical design flexibility, M Line (Master) motors can be applied on a wide variety of applications with different operational requirements. In addition the M Line can be easily modified to match existing motors. H Line (High Performance) motors have been designed in such a way to withstand the most demanding applications and are regarded as both a reliable and low maintenance cost solution under such conditions.

With the application of modern software’s which were developed in conjunction with Universities of Europe, USA and Brazil ensuring high design accuracy, WEG provides superior performance from these machines. Optimized design, quality of materials used, associated with manufacturing process duly controlled on all production phases make these motors suitable for several market segment applications including mining, sanitation, cooling systems, cement, oil and gas, steel plants, pulp and paper and others. In order to comply with highly demanding world markets, WEG has its Quality System certified by Bureau Veritas Quality Institute in accordance with ISO 9001 requirements. As well as ISO 14001 environment certification, all WEG medium and high voltage motors are also certified by internationally recognized certifying institutions such as CSA (Canada) and PTB (Germany).

M Line - Master

Output ratings up to 50,000kW (70,000HP) Voltages ranging from 220 to 13,800V Speed from 3600 to 300rpm M Line motors are manufactured in different configurations in reference to cooling methods and degree of protection. As a result, a motor configuration can be defined in such a way to better meet operating and environment conditions. Motor supplied in frame sizes IEC 280 to 450 (NEMA 4400 to 8000) are manufactured in cast iron frames. Those motors manufactured in frame sizes IEC 500 (NEMA 8800) and larger have their frames built in welded steel plates. Main advantages in using WEG M Line motors include: - High efficiency - Degree of Protection IP23 (WP-I), IP(W)24 (WP-II) or IP(W)55 / IP(W)56 / IP(W)65 - Reduced noise level - Low and easy maintenance - Can be built to meet API 541 standards - Squirrel cage rotor Slip ring (wound rotor) - Bearings Oil lubricated sleeve bearings Grease or oil lubricated ball or roller bearings - Interchangeability with existing motors.

M Line Nomenclature

M

G

MOTOR LINE M – Master Line ROTOR TYPE G – Squirrel cage A – Slip ring (Wound rotor) COOLING METHODS A – Open self-cooled D – Self-cooled by ducts, air inlet and outlet T – Forced cooling, air inlet and outlet by ducts V – Forced cooling, cooling on top of motor and air outlet by ducts F – Self-cooled with air-to-air heat exchanger, heat exchanger on top of motor R – Self-cooled with air-to-air heat exchanger, heat exchanger around the stator I - Forced cooling on the internal and external air flow, air-to-air heat exchanger W – Air-to-water heat exchanger L – Air-to-water heat exchanger, forced cooling on the internal air flow FRAME IEC 280 to 1800 NEMA 4400 to 28,000 FEET HOLES IEC (S, M, L, A, B, C, D, E) NEMA (06,07,08,09,10,11...)

F

560

A

H Line - High Performance

Output rating from 100 to 3150kW (135 to 4000HP) Voltages from 220 to 6900V Speed from 3600 to 600rpm With simple and compact construction, H Line motors are widely used due to their high reliability making them suitable for the majority of the driven machines found in industries. The frame construction consists of a high resistance solid block and it is fitted with external cooling fins. The whole cooling system, which consists of an internal and an external air flow, provides an homogeneous blow of cooling air inside the frame for maximum performance of such motors. Main advantages in using WEG H Line motors include: - High efficiency - Degree of Protection IP(W)55 / IP(W)56 / IP(W)65 (TEFC, TEBV) - Reduced noise level - Low and easy maintenance - Robust solid high strength cast iron construction Can be built to meet IEEE841 (2001) mill and chemical duty Can be built to meet API541 standards - Bearings Oil lubricated sleeve bearings Grease or oil lubricated ball or roller bearings - Cooling Self cooling Forced cooling, usually required for VFD applications. - Interchangeability with existing motors - Internal air flow - Heat exchanger not required.

H Line Nomenclature H MOTOR LINE H - High Performance Line ROTOR TYPE G – Squirrel cage COOLING SYSTEM F – Enclosed, finned, internal and external air flow FRAME IEC 315 to 630 NEMA 5000 to 10,400 FEET HOLES IEC (L, A, B, C, D, E) NEMA (06,07,08,09,10,11...)

G

F

450

A

Applications

Squirrel Cage Motors Due to their design versatility and excellent operating conditions, H and M Line motors are used on a wide variety of applications in the industry. Among other equipment, they are used to drive machines and equipment that require either variable or constant torque applications such as fans, pumps, grinders, conveyor belts, compressors, laminating machines, mixers and others. Slip Ring Motors Slip ring motors are usually applied on high inertia loads or on high resistant starting torque loads. They are also required when there is starting current limitations on the power supply system. The most common loads driven by these motors are: ball mills, crushers, fans, exhausters, shredders and grinders for cement and mining industries, steel plants, among others. These M Line slip ring motors can be supplied with motorized brush-holder system or fixed brush-holder system, as required by the load and operating conditions. Slip ring motors fitted with motorized brush-holder system offer important advantages in terms of maintenance once they allow the brushes to be in contact with rings only during motor starting. Hence, avoiding brushes and slip rings wear.

Supply: MAF400, 331kW (440HP), 6600V, 6 poles Application: Conveyor belt

Supply: MGF8809, 930kW (1240HP), 4160V, 2 poles Application: Pump

Supply: MGF630, 1070kW (1430HP), 13,200V, 8 poles Application: Pump

Vertical Shaft Motors WEG also offers medium and high voltage vertical shaft motors. These motors can be supplied with either grease lubricated ball or roller bearings, or angular contact bearings. Depending on the application, specially when subject to high inertia and high thrust loads, vertical motors can be supplied with oil lubricated roller bearings or sleeve bearings. H and M vertical shat motors are designed and manufactured to meet customer requirements for pump, crusher, mixer applications, among others.

Hazardous Area Motors For explosive atmosphere applications, WEG manufactures motors with specific safety characteristics and suitable to operate in areas where flammable products are continually handled, processes and storaged so as to avoid personnel injury and damage to facilities. EEx e (increased safety) and EEx n (non sparking) motors are supplied in H and M Lines, while M Line also allows EEx p (pressurized) application. Explosive atmosphere motors comply with national and internationally recognized standards and are tested and certified by renown worldwide certifying institutions.

Supply: HGF450, 1170kW (1570HP), 480V, 6 poles Application: Grinder

Supply: MAF450, 920kW (1230HP), 4160V, 4 poles Application: Ball mill

Supply: HGF355, 290kW (390HP), 3300V, 4 poles Application: Centrifugal pump

Supply: HGF450, 630kW (845HP), 6600V, 2 poles Application: Blower

Supply: HGF450, 810kW (1086HP), 4000V, 6 poles Application: Debarker

Constructive Characteristics

Frame Manufactured either with welded steel plates or cast iron, the frame is motor structural component that accommodates, supports and protects the active magnetic part of the motor. Its rugged construction offers excellent mechanical strengthen to the motor along with low vibration levels. Stator Regarded as the static magnetic part of the motor, the stator consists of a steel laminated core. The coils forming the stator winding are fitted into the lamination core slots. The stator core is mounted directly on the motor frame. Winding The winding process supplied by WEG is specially designed and specified for the voltage and application they are intended for. Medium and high voltage motor coils are manufactured with rectangular copper wire, form-coiled and totally mica tape insulated. Conductive and semi-conductive tapes are also used to insulate the coils to ensure improved resistance to corona effect.

Frame

Winding

Rotor

Rotor Regarded as the rotating component in the electric motor, the rotor consists basically of a shaft and a steel lamination core. On slip ring motors, either the squirrel cage or the rotor coils are fitted into the lamination core slots. The squirrel cage can be built with aluminum die cast or with copper or brass. The rotor is designed taking into consideration the required starting torque and motor operating conditions. Shaft is manufactured with several types of thermally treated steel such as AISI/SAE 1045, 1524 or 4140. Insulation System WEG MICATHERM insulation system is based on the “Vacuum Pressure Impregnation” (VPI) system, which was developed in conjunction with renown suppliers of insulating materials all over the world. Applying special epoxy resin, this system provides perfect to the motor protection process which has no emission of harmful gases to the environment. The VPI system for many years has been reliable and efficient on electric rotating machines for a wide variety of applications. The insulation system is applied on medium and high voltage machines manufactured with form coils ranging from 380 to 15,000V. Balance WEG counts on a series of equipment to perform balance up to 3600rpm. Computerized equipment allow accurate balance on all rotors. As a consequence, WEG motors present significantly reduced noise levels. The standard balance is provided in two planes. However, the company has the capability of providing three plane balancing whenever required or when requested by the customer.

Balance

Vacuum Pressure Impregnation (VPI)

Machining

Cooling System

WEG medium and high voltage motors can be supplied with usual cooling methods which may vary based on the type of machine to be driven, by the application and environment conditions.

H LINE Totally Enclosed Self-cooled IC411 (TEFC) IP(W)55 / IP(W)56 / IP(W)65 Totally enclosed Forced cooling IC416 (TEBV) IP(W)55 / IP(W)56 / IP(W)65

M LINE Totally enclosed Air-to-air heat exchanger IC611 (TEAAC) IP(W)55 / IP(W)56 / IP(W)65 MGF, MAF Totally enclosed Air-to-water heat exchanger IC81W (TEWAC) IP(W)55 / IP(W)56 / IP(W)65 MGW, MAW

M LINE Totally enclosed Independent cooling Air-to-water heat exchanger IC86W (TEWAC) IP(W)55/IP(W)56/IP(W)65 MGL, MAL Totally enclosed Independent cooling Air-to-air heat exchanger IC666 (TEAAC) IP(W)55/IP(W)56/IP(W)65

Contaminated area

Non-contaminated area

Non-contaminated area

Non-contaminated area

Totally enclosed Self-cooled by ducts IC31 (TEPV) IP(W)55/IP(W)56/IP(W)65 MGD, MAD

Contaminated area

Non-contaminated area

Non-contaminated area

MGT, MAT

Non-contaminated area

Contaminated area

Non-contaminated area

Totally enclosed Independent cooling by ducts IC37 (TEPV) IP(W)55/IP(W)56/IP(W)65

Contaminated area

Non-contaminated area

MGI, MAI

Open (Self-cooled) IC01 (ODP) IP23 (WP-I) IP(W)24 (WP-II) MGA, MAA, MGP, MAP Open Independent cooling IC06 (OIV) IP23 without ducts IC26 (OIV) IP(W)24 with ducts MGV, MAV

Warm air

Warm air Cold air

Cold air

Could air

Could air

Accessories and Special Features

Accessories and Special Features WEG medium and high voltage motors are supplied with standard accessories required for their correct operation and/or for monitoring of the main components. When specifying the motor, buyer must include additional accessories and special features to be included. Standard Accessories - Temperature detectors - PT-100 – in the stator winding - Temperature detectors - PT-100 – in the bearings - Space heaters - Shaft grounding brushes for VFD applications, or all motors in frame size 450 and larger. Special Accessories - Vibration detectors - Bearing Thermometer Oil thermometer Oil flowmeter Lubrication hydraulic unit Oil pressure system (Hydrostatic Jacking) - Capacitors - Lighting arresters - Current transformer (CT) - Independent cooling - Temperature detectors for air inlet and outlet (cooling) - Air thermometer (cooling) - Position indicators (encoder or tacho-generator) - Air-to-water heat exchanger Water flowmeter Water flow sight glass Water thermometer

PT-100 in the bearing

- Water leakage indicator - Anchorage plate - Noise muffler - Surrounding muffler - Speed non-reversing ratchet (vertical shaft motors) - Rail base Special Features - Mounting - Special painting - Class H insulation (only for low voltage) - Reduced vibration level - Reduced noise level - Degree of Protection IP56 / IP65 - Labyrinth taconite - Sleeve bearing - Oil lubricated ball or roller bearings - Oil-Mist bearings - Special shaft: Tapered shaft end Double shaft end Hollow shaft Special shaft end - Squirrel cage rotor material Copper Brass - Modified main connection box - Additional main connection box - Protection for classified area motors EEx n (Non spaking) NEC EEx e (Increased Safety) NEC EEx p (Pressurized) NEC

Thermometer

Sleeve bearings

Rail Base

Tapered shaft Labyrinth taconite

Surrounding Muffler

Pressurized system for classified area

Testing Laboratory

All WEG motors are tested in a modern laboratory in accordance with IEC 6034-1 Standards, NEMA MG1 and IEEE 112. With testing capacity for medium and high voltage motors up to 10,000kVA and voltages up to 15,000V, the WEG testing laboratory is computer monitored and controlled for extreme accuracy. Tests are divided in three groups: routine, type and special tests. Routine tests are performed on all motors produced. Besides routine tests, type and special are usually performed on one jiece in a batch of identical machines or under customer request.

Test Laboratory

Control Room

Surge Test

Routine Tests Resistance measurement at cold No load test Locked rotor test Hi-pot test Insulation resistance test

Type Tests All routine tests Vibration measurement at cold Breakdown test Temperature rise test Load test at constant voltage

Special Tests Noise level Shaft voltage Overspeed Vibration analysis Curve performance Full spectrum noise

Service and Costumer Services

Customer Services WEG offers its customers complete service and after service support. Included in this package of services are response to general requirement and field service such as identification of problem causes and commissioning of machines. In addition to that, its skilled Service Team is permanently available to give prompt support all over the world. Manuals supplied together with the equipment provide detailed and precise information related to safety, installation and maintenance instructions. WEG Service Department counts on a qualified and well-trained team capable to provide support on any field requirement with the application of modern equipment so as to ensure reliable results.

Service As leading provider of motors and generators, WEG offers a complete package of additional services to its customers including repairs, rerating of small and large size machines, including other manufacturers machines, specialized applications within the following scope: - DC traction motors and generators (AC) - Squirrel cage and slip ring motors in output ratings up to 50,000kW (70,000HP) and voltages up to 13,800V - Synchronous generators, brushless or with brushes, medium and high voltage When performing repair services, WEG employs the same technology and facilities used on the plant manufacturing process for superior performance.

632.10/062005

WEG EXPORTADORA Av. Prefeito Waldemar Grubba, 3000 89256-900 - Jaraguá do Sul - SC - Brazil PHONE: 55 47 372-4002 - FAX 55 47 372-4060 www.weg.com.br