Product Presentation Motors Part I

BCH

PRODUCT PRESENTATION Electric Motors

Product Presentation

Series Motors

Business Objective

BCH

 To address growing A. C. motor market by offering wide, versatile, technically and commercially most competitive product range.  To offer complete solution to customers integrating Motor product offer with Soft Starters & A. C. Drives.  To become a one of the major player in motor market by achieving minimum 10% market share in next 5 years time & then go ahead with leadership role in this business. Product Presentation

Series Motors

Business Objective

BCH

Why in motor business?  Over 4 decades of experience in electrical industry.  Strong brand image in OEM & End User segment.  Outstanding reputation as consistent Quality manufacturers.  Excellent reach across the country with 30 branch offices, 150 resident engineers and over 600 channel partners.  Strong team of qualified sales & application engineers.  Complete range of Soft Starters, A. C. Drives, MCC & conventional electromagnetic starter range, which has got a synergy with motors. Product Presentation

Series Motors

BCH

MARKET ANALYSIS & BUSINESS PLAN Product Presentation

Series Motors

Indian Market Size for LV Motors 1Rs.105 Crores

7%

Alstom

Rs.210 Rs.210 Crores

*

14%

BCH

•Others NGEF, ELGI Electric, JYOTI, GEMI Motors, LHP & Hindustan 1

Rs.120 Rs.120 Crores

8%

Rs.495 Rs.495 Crores

Brand Leader

33% Crompton Greaves

Siemens

Greaves

TOTAL LV MOTOR MARKET Volume – Rs. Rs. 1500 Crores. Crores. Qty – 10,000,00 Nos. motor p. a.

Rs.120 Rs.120 Crores

8%

Bharat Bijlee

Rs.300 Rs.300 Crores

20%

ABB

Product Presentation

Rs.150 Rs.150 Crores

10%

Kirloskar Electric

Series Motors

Typical Relation – Quantity & Value Frame group-wise relation LV Range More quantity in higher frames means higher Top & bottom line.

Value

5S 31 M 160

e m a fr L 55 3 –

36% 36%

Qty. 4%

9%

ame r f 0M 8 2 –

87%

35% 35%

56 – 132M frame

29% 29% Product Presentation

BCH

Series Motors

List Price Positioning

List Price

25% % of BCH Proposed Price Level

BCH

20% 15% 10% Kirloskar 5%

Electric

Bharat Bijlee

Alstom ABB

Siemens

0% -5%

CGL7%

-10% -15%

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Series Motors

Delivery Schedule Commitment

BCH

General Purpose Standard Motors

Industry Standard

• Frame Size up-to 132M

- 1 / 2 weeks

• Frame Size > 132M and < 250M

- 3 / 4 weeks

• Frame Size > 250M and up-to 355L

- 4 / 6 weeks

5% Inverter

Duty Motors

• All Frame sizes

- 4 / 6 weeks

Delivery up-to 132M will be improved to ex-stock with monthly projections

Product Presentation

Series Motors

BCH

APPLICATION AREAS Product Presentation

Series Motors

LV Motors – Major Application Areas

BCH

Major Basic Applications

•

Pumps

– Centrifugal, Reciprocative, Vacuum, Screw, Axial Flow, Mixed Flow

• Fans – ID, FD, Centrifugal/+ Displacement Blower, Axial / Mixed Flow, Rotary • Compressors - Centrifugal, Reciprocating, Rotary, Screw • Conveyors – Belt, Chain • Crushers 5%– Cone Crusher, Roll / Jam Crusher, Pulp Grinder • Agitators – Agitator, Centrifuge (extractor) 7%

• Ball Mills – Ball Mill, Hammer Mill • Re-rolling Mills Product Presentation

– Rollers, Rolling Mill Series Motors

LV Motors – Major Application Areas • Steel - for Roller Tables, Cranes, Hoists, Mudgun, Charging Cars, and other Special Applications. • Power Plants - for Material Handling Equipments, Conveyors, Boiler Feed Pumps, Cooling Towers & ID / FD Fans. • Railways - for use in Locomotive Blowers, Loco - Air Compressors, Exhausters, and Arno Converters. • Coal and 5% Oil Mines - for applications in Haulage, Mine Ventilation, Pumps - for use underground, Side Load Dumpers, Material Handling Equipments, Sucker 7% Rod Pumps for Oil Mines & Oil Rigs. • Cement Industry - for Energy Efficient VVVF, Drive Applications. • Petrochemicals Industry – for Increased Safety (’e’) applications. Product Presentation

Series Motors

BCH

LV Motors – Major Application Areas

BCH

• Jute and Textiles - for use in Spinning, Twisting and Ginning mills. • Machine Tools Industry - for use in Lathes, Drilling Machines, Milling Machines, Shearing, Press & Punching Machines. • Offshore - for Marines, Shipyards, Defense Services, Army Research Centers etc. • Paper Industry - for use in Pulpers, Chippers & Boiler Feed Pumps. • Miscellaneous Applications - including Pumps, Fans , Blowers, 5% Agitators, Mixers, Flour Mills, Saw Mills, Grinders & Compressors. • Material Handling - Hoists, Cranes, Lifts, Vibrating Screens, 7% Conveyors, Feeders etc. and other applications • Sugar

– Sugar Centrifuge, Cane Unloader.

Product Presentation

Series Motors

BCH

MOTOR BASICS

Product Presentation

Series Motors

Standards - Motors

BCH

Indian Standard - IS: 325 - 1976 International Standard IEC 60034 - 1 European Standard EN 60034 - 1 * GLOSSARY * BIS / IS: Bureau of Indian Standard / Indian Standard. * IEC: International Electromechanical Commission. * EN: Standards published by European Committee. for Electro technical Standardization.

Product Presentation

Series Motors

Standards for Motors - An Overview Description

Indian Standards

Intl. Standards

Rating and performance

IS: 325-1996

IEC 60034-1

Methods for determining losses and efficiency

IS: 12615-2004

IEC 60034-2

Classification of degrees of protection

IS: 4691-1985

IEC 6003460034-5

Methods of cooling

IS: 6362-1971

IEC 60034-6

Symbols of construction and mounting

IS: 2253-1974

IEC 60034-7

Terminal markings and direction of rotation

IS: 4728-1975

IEC 60034-8

Noise limits

IS: 12065-1987

IEC 60034-9

IS: 1231-1974 (Foot Mtg.) IS:2223-1983 (Flange Mtg.)

IEC 60072-1

IS: 12075-1987

IEC 60034-14

Dimensions and output for electric machines Vibration limits

Other Standards: Energy Efficiency: IEEMA: 19-2000; CEMEP* Agreement. Inter Plant Standard for Steel Industries: IPSS –1-03-007.

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BCH

* CEMEP: European committee of Manufacturers of Electric Machines & Electronics.

Series Motors

Three Phase Motor Construction Rotor Bars

BCH

Eye Bolt Terminal Box Rotor Stator Winding Drive End End Shield

Fan

Shaft Non Drive End End Shield

Shaft Key

Rotor End Rings Bearings

Fan Cover

Motor Feet or Base

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Stator Enclosure

Mounting Hole

Series Motors

Motor Terminology

BCH

Supply Voltage (V) - 3 phase alternating current power supply at which motor terminals are connected. Generally this power supply is 415 volts as standard. Sometimes, it is mentioned as 380 volts or 440 volts or 550 V (mining applications). Supply voltage up-to 1000 V A.C. is known as low voltage category & corresponding motors are known as LV motors or LT motors. Supply voltage > 1000 V A.C. & up-to 33 KV is known as medium voltage category & corresponding motors motors are known as Medium Voltage motors or HT motors.

Frequency (F) - Frequency, in cycles per second, of AC power; usually known as 50 Hz in India & European countries & 60 Hz in USA & Canada.

Combined Voltage & Frequency Variation - Maximum variation in supply voltage and Frequency in a particular motor determined either by standard and / or by mutual agreement between motor manufacturers & customers. As per IEC & IS, permissible variations are: Voltage + 6%, Frequency + 3% and Combined + 9% (absolute sum). However, all motor manufacturers are presently Offering motors with V / F / VF variation of + 10% / + 5% / + 10% (absolute sum).

Product Presentation

Series Motors

Motor Terminology

BCH

Frame Size Usually refers to the IEC and IS standardized motor mounting dimensions, which facilitates interchangeability. Frame size is expressed in mm & it is the height (distance) between the center of shaft & end of base. For each frame size, there are possibility of 3 no. lengths of motor i.e. S (Short), M (Medium) & L (Long). Different output ratings are obtained at different frame sizes as per the standard irrespective of manufacturers. Hence, it facilitates interchangeability. Standard frame sizes (total 26 nos.) as per IEC & IS are described below: Frame Size

Frame Size

Frame Size

Frame Size

• 56

• 100L

• 180M

• 280M

• 63

• 112M

• 180L

• 315S

• 71

• 132S

• 200L

• 315M

• 80

• 132M

• 225S

• 315S

• 90S

• 160M

• 225M

• 355S

• 90L

• 160L

• 250M

• 355M

• 280S

• 355L

Product Presentation

Series Motors

Motor Terminology

BCH

Enclosure for LV Motors ‰ Holds different parts & internal components together. ‰ Helps with heat dissipation. ‰ In some cases, protects internal components from the environment. Enclosure defines the motor construction according to environmental protection and method of cooling. For LV motors, these types includes (as per IEC / IS): Totally Enclosed Fan Cooled (TEFC) – Totally enclosed enclosure with external cooling means, such as a shaft connected fan. There are external fins for effective cooling. Screen Protected Drip Proof (SPDP) – Intended for indoor application only. Enclosure is protected through wire mesh with cooling fan inside the enclosure. No external fins. Totally Enclosed Blower Cooled (TEBC) - Totally enclosed enclosure with external cooling means such as a separately controlled motor / blower. Explosion-Proof or Flame Proof (FLP) - A totally enclosed fan cooled (TEFC) motor designed to withstand an internal explosion of specified gases or vapors and not allow the internal flame or explosion to escape.

Product Presentation

Series Motors

Motor Terminology

BCH

Degree of Protection IP According to the IEC 60034-5 & IS: 4691-1985, standard the electric motors are provided with IP code which determines the degree of protection ensured by the enclosure against access to dangerous parts, introducing foreign matter and/or water. The IP code consists of IP code letters and two obligatory digits, meaning The first digit

The second digit

(protection from introduction of solid foreign matter)

(protection against penetration of water and its harmful effects)

IP

Definition

IP

Definition

0

no protection

0

no protection

IP55

1

diameter > 50 mm

1

dropping vertically

2

diameter ≥ 12,5 mm

2

dropping (up to 15° )

As Standard Offer

3

Diameter > 2,5 mm

3

sprayed

4

Diameter > 1,0 mm

4

splashed

5

limited protection against dust Complete protection against dust

5

splashed

6

in strong stream

7

under short-time immersion

8

under permanent immersion

6

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Other Options

IP44 IP 54 IP56 IP65

Series Motors

Motor Terminology

BCH

Ambient Temperature & Temperature class The temperature of the space around the motor. Most motors are designed to operate in an ambient not over 40°C (104°F) or 450C (1130 F) or 500 C (1220F), depending up-on country, standard, specification & motor design. Note: A rating of 50°C Ambient is not the same as a rating of 50°C Rise; see Temperature Class.

Motor insulation is rated by temperature class ‰ ‰ ‰ ‰ ‰

Class A – 105°C total temperature Class E – 120°C total temperature Class B – 130°C total temperature Class F – 155°C total temperature Class H – 180°C total temperature

500C ambient temperature as Standard Offer by BCH

Motors are designed to maintain max. temperature within insulation class limits (or lower). High Ambient temperature (> 500C) reduces allowable rise of motor windings resulting in higher insulation or larger motor. Product Presentation

Series Motors

Motor Terminology

BCH

Altitude ‰ Thin air reduces cooling capacity of the motor resulting in higher temperature rise. ‰

All standard motors are designed for an altitude of 1,000 meters above Mean Sea Level (MSL)

‰ Temperature limits must be derated by 3% to 5% for each 500 meters above basic 1,000 meters (above MSL), up-to 4,000 meters altitude. ‰ Higher altitude may result in larger motor. Altitude Output (%) 1000 M 100% 1500 M 97% 2000 M 94% 2500 M 90% 3000 M 86% 3500 M 82% 4000 M 77%

Product Presentation

Table showing deration in motor rating due to higher altitude.

Series Motors

Motor Terminology

BCH

Mounting Reference standard for mounting: ‰ IS: 1231 - 1974 (IEC 60072-1 / EN 50347): for Foot Mounted Motors (B3). ‰ IS: 2223 - 1983 (IEC 60072-1 / EN 50347): for Flange Mounted Motors (B5/B14)

There are five basic mountings are available: Horizontal Foot Mounting (B3) 1 IM B3 / IM 1001 FRAME (56-355) – WITH FEET SHAFT-HORIZONTAL MOUNTING-BASE OR RAILS

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Horizontal Flange Mounting (B5) 2 IM B5 / IM 3001 FRAME (56-355) – W/O FEET SHAFT-HORIZONTAL MOUNTING-FLANGE TYPE D

Series Motors

Motor Terminology

BCH

Mounting (Contd…) Horizontal Face Mounting (B14)

Horizontal Foot cum Flange Mounting (B35)

3

5

IM B14 / IM 3601 FRAME (56-132) – W/O FEET SHAFT-HORIZONTAL MOUNTING-FLANGE TYPE C

IM B34 / im 2101 FRAME (56-132) – WITH FEET SHAFT- HORIZONTAL MOUNTINGBASE/FLANGE TYPE C

Another ten different mountings arrangements can be derived from above five basic versions: 6 IM B6 / IM 1051

FRAME (56-355) – WITH FEET SHAFT- HORIZONTAL MOUNTING-WALL HORIZONTAL FOOT

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7 IM B7 / IM 1061

FRAME (56-355) – WITH FEET SHAFT-HORIZONTAL MOUNTING-WALL HORIZONTAL FOOT

8 IM B8 / IM 1071

FRAME (56-355) – WITH FEET SHAFT-HORIZONTAL MOUNTING-WITH FEET HORIZONTAL FOOT

9 IM V1 / IM 3011

FRAME (56-355) – W/O FEET SHAFT - FACE VERT. DOWN MOUNTING-FLANGE TYPE D VERTICAL FLANGE

Series Motors

Motor Terminology

BCH

Mounting (Contd…) 10

11

IM V5 / IM 1011

FRAME (56-355) – WITH FEET SHAFT-FACE VERTICAL DOWN MOUNTING-BASE OR RAILS VERTICAL FOOT

13 IM V6 / IM 1031

FRAME (56-355) – WITH FEET SHAFT - FACE VERTICAL MOUNTING WALL VERTICAL FOOT

IM V15 / IM 2011

FRAME (56-355) – WITH FEET SHAFT - FACE VERTICAL DOWN MOUNTING-WALL OR FLANGE VERT. FOOT CUM FLANGE

14 IM V18 / IM 3611

FRAME (56-132) – W/O FEET SHAFT - FACE VERT. DOWN MOUNTING-FLANGE TYPE C VERTICAL FACE

12 IM V3 / IM 3031

FRAME (56-355) – W/O FEET SHAFT - FACE VERT. DOWN MOUNTING-FLANGE TYPE D VERTICAL FLANGE

Total 15 mounting possibilities from 5 basic versions

15 IM V19 / IM 3631

FRAME (56-132) – W/O FEET SHAFT - FACE VERT. UP MOUNTING-FLANGE TYPE C VERTICAL FACE

All face mounting (B14 or it’s variants can be offered in 160M & 160L too as a special case

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Series Motors

Motor Efficiency (% η)

BCH

Losses*

Electrical Input

Power Flow Through Motor

Output Efficiency in % = ------------ x 100 Efficiency in % = Input * Losses

Product Presentation

Mechanical Output Output ------------------ x 100 Output + Input

Series Motors

Thermal withstand & Starting Time

BCH

Locked Rotor Withstand Time or Thermal Withstand Time It is the time taken by the motor windings or rotor to reach the maximum limiting temperature, during locked rotor condition, depending upon class of insulation, from either ambient temperature or rated service temperature. It is expressed in SECONDS either as COLD (i.e. when a motor is started from normal ambient condition in the winding) or HOT (i.e. when the motor is started from it’s service condition & winding reached stabilized operating temperature).

Starting Time or Accelerating Time It is the time taken by the motor to come to it’s rated speed, when connected to load. Starting time or Accelerating Time depends on: ‰ Total inertia of the system I.e. GD2 value of the load referred to motor shaft speed Plus motor GD2. ‰ Speed Torque Characteristics of the motor ‰ Speed Torque Characteristics of the load.

Starting Time should always be less than Thermal Withstand Time.

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Series Motors

Tests

BCH

Routine & Type Tests are conducted by the manufacturers as per IS: 325-1978. These tests includes: Routine Test (To be conducted on each motor) Insulation Resistance, High Voltage, Full Load Speed at 57% rated voltage, No Load Test and Locked Rotor Test. Type Test (To be conducted on similar motor & record to be maintained) ™ Stator winding resistance, No load test, Reduced voltage running up test, and Locked rotor test ™ Full load test, Temperature rise test, Momentary overload test and Insulation resistance test There are optional tests like Noise level test, Vibration test, degree of protection test etc. Motor manufacturers should have adequate facility to conduct routine & type tests.

Product Presentation

Series Motors

Motor Selection Criteria

BCH

Features • • • • • • •

Meteorological data - environmental data. Power supply. Location. Application data - driven equipment data. Other features & accessories. Performance. Standard.

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Series Motors

Motor Selection Criteria

BCH

Meteorological Data • • • • •

Ambient temperature. Altitude. Rain fall. Humidity. Climate condition - dusty atmosphere. - chemically polluted. - hazardous gaseous. • Seismic condition.

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Series Motors

Motor Selection Criteria

BCH

Power Supply • • • • •

Voltage - LT & HT. Frequency. Voltage & frequency variation. No of phases. Fault level.

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Series Motors

Motor Selection Criteria

BCH

Location • Indoor - Dry atmosphere. - Humid atmosphere. • Outdoor - Under the shelter. - Open to sky.

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Series Motors

Motor Selection Criteria

BCH

Application Data • • • • • • •

Mounting - foot / flange / face. Special mounting. Enclosure - TEFC, SPDP etc. Cooling - air, water or other. Bearings. Lubrication. Terminals & terminal box.

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Series Motors

Motor Selection Criteria

BCH

Application Data • Temperature rise - class ‘B’ limit with class ‘ F’ insulation. • Method of starting - DOL, ATS, Star-delta. • No. Of starts - hot, cold & equally spread in hour. • Vibration limit. • Noise level. • High speed bus transfer capability.

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Series Motors

Motor Selection Criteria

BCH

Application Data • Under voltage starting & running. • Duty - S1,S2, ………….etc. • Over load - Continuous over load. - Momentary over load. • Over speed - 120% for 15 minute. • Critical speed - upper & lower critical speed. • Insulation class - B , F or H.

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Series Motors

Motor Selection Criteria

BCH

Driven Equipment Characteristics

• Speed of operation. • • • • • •

Torque-speed characteristics. Moment of inertia. Method of coupling. Direction of rotation. Short time over load. Shaft extension.

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Series Motors

Motor Selection Criteria

BCH

Special Application • Railway • • • • • •

- wide voltage & atmospheric variation. Cyclic duty - short time,braking (S2 - S8). Multi speed - two, three or four speed. Mechanical/ electrical braking. Parallel operation. Low vibration. Textile / submersible & others.

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Series Motors

Motor Selection Criteria

BCH

Accessories • Embedded temperature detector. - RTD & BTD. - Thermister. - Thermo couple/ Thermostat. - Dial type thermometer. • Space heater. • Bearing condition monitoring. • Speed switch. Product Presentation

Series Motors

Motor Selection Criteria

BCH

Performance • • • • •

% Efficiency. Power factor. Speed / Slip. Starting Torque. Starting Current.

Product Presentation

Series Motors

Motor Selection Criteria

BCH

Standard • Reason for standardization. - Rating, speed. - Supply voltage,frequency, phase - Frame size & rating v/s frame. - Enclosure & mounting etc. • Indian standard. • International standard.

Product Presentation

Series Motors