MAGNETIC PUTTY PRESSING

VACCUM PRESSURE IMPREGNATION

INSTALLATION
Stator Winding Overhang
 CONSTRUCTIONAL FEATURES OF AC MACHINES

ROTOR

• SHAFT
• LAMINATED ROTOR CORE
• ROTOR WINDING
• INTERNAL FAN
• SLIP RINGS/ EXCITER
 ROTORS

1. SHAFT [Link] CONNECTION S

2. FAN 10. EXCITER C
3. SC RING 11. DAMPER WDG I
4. CORE 12. FIELD WDG M
5. WINDING BARS
6. SLIP RINGS
7. DBL LAYER WDG
8. BANDAGING

S
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Y
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CYLINDRICAL ROTOR
SALIENT POLE ROTOR
INDUCTION BRAZING OPERATION
ULTRASONIC TESTING OF ROTOR
BAR JOINTS
 SLIP RING AND BRUSHES
SLIP RINGS
ADEQUATE CURRENT CARRYING CAPACITY
STEEL/STAINLESS STEEL RINGS
COPPER STUDS
HELICAL GROOVING(>30m/s)

BRUSHES
METAL GRAPHITE ( M 15 E) FOR  < 28m/s
ELECTRO GRAPHITE ( EGOR) FOR  > 28 & <40m/s
NATURAL GRAPHITE FOR  > 40m/s
MOUNTING OF BRUSHES ON SLIP RING
SLIPRING & BRUSHGEAR ARRANGEMENT IN
LINE-F MOTORS
 BEARINGS

ROLLING ELEMENT BEARINGS

BALL AND ROLLER BEARING ON DRIVE END
ROLLER BEARING ON NON DRIVE END

SLEEVE BEARINGS
ENDSHIELD MOUNTED SLEEVE BEARINGS
PEDESTAL MOUNTED SLEEVE BEARINGS
RING LUBRICATED
FORCED OIL LUBRICATED
HIGH PRESSURE JACKING
ANTIFRICTION BEARING ARRANGEMENT
(HORIZONTAL MOTORS)
FLANGE MOUNTED SLEEVE BEARING
ASSEMBLY
 TERMINAL BOX
TYPES –
1) PHASE SEGREGATED TYPE (PSTB) – SUITABLE FOR FAULT
LEVEL OF 500 MVA FOR 0.25 SEC AND NOMINAL CURRENT UP
TO 450 AMPS
A) DIRECT TERMINATION TYPE
B) WITH TAIL CABLE ARRANGEMENT
2) PHASE SEPARATED TYPE – SUITABLE FOR FAULT LEVEL OF
750 MVA AT 11 KV FOR 0.25 SEC AND NOMINAL CURRENT UP
TO 1200 AMPS
3) ELASTIMOLD CONNECTOR - SUITABLE FOR FAULT LEVELOF
25KA AT 11 KV for 0.17 SEC. AND NOMINAL CURRENT UP TO
1500 AMPS
4) ROD TYPE – FOR NOMINAL CURRENT > 1500 A
5) FLAME PROOF TB – FOR Ex’d’ & Ex’p’ MOTORS. SUITABLE
FOR FAULT LEVEL OF 500 MVA FOR 0.25 SEC.
PHASE SEGREGATED BOX WITH DIRECT TERMINATION
 INSULATION

RESIN POOR (VPI) MICALASTIC INSULATION SYSTEMS

Normally used for Large Range Motors (Stator OD > 1000 mm) or as per
customer requirements.
Epoxy Mica Glass baked tapes initially with low resin content and final
impregnation by Vacuum Pressure Impregnation system.

RESIN RICH MICALASTIC INSULATION SYSTEMS

Used for Medium Range Motors (Stator OD<1000 mm).
Epoxy Mica Polyester baked tapes initially with high resin content and final
impregnation by Roll Impregnation system.

HYBRID INSULATION
It is the feature of H-Series machines, but can be used in Line-7 & Line-F
series machines also.
Alternate layers of Glass baked & Polyester baked tapes and final
impregnation by Vacuum Pressure Impregnation system.
This type of impregnation ensures
▪ A void free insulation so that there is no corona discharge in operation

▪ Good thermal contact between the winding and stator core which ensures
good cooling

▪ High electrical and mechanical strength

▪ Better life

▪ High switching and reversing strength

▪ Suitability for converter operation

▪ High thermal durability

 TESTING(IS4029)

ROUTINE TESTS - CONDUCTED ON ALL MACHINES

1) MEASUREMENT OF RESISTANCE OF WINDINGS OF
STATOR AND WOUND ROTOR.
2) INSULATION RESISTANCE TEST
3) RES. AND I.R. OF RTDs,BTDs AND SPACE HEATERS.
4) NO LOAD TEST
5) LOCKED ROTOR READINGS OF VOLTAGE, CURRENT AND
POWER INPUT AT A SUITABLE REDUCED VOLTAGE.
6) REDUCED VOLATGE RUNNING UP TEST.
7) OPEN CKT. VOLTAGE TEST.
8) P.I. AND HIGH VOLTAGE.
9) VIBRATION MESUREMENT(IS12075)
10) SHAFT VOLTAGE MEASUREMENT
 TESTING(IS4029)
TYPE TESTS – CONDUCTED TO PROVE THE DESIGN
1) FULL LOAD TEST TO DETERMINE EFFICIENCY, POWER
FACTOR AND SLIP.
2) TEMPERATURE RISE TEST
3) MOMENTARY OVERLOAD TEST.
4) NOISE LEVEL OF MOTOR(IS 12065)
5) OVER SPEED TEST etc.

SPECIAL TESTS (FOR SPECIFIC REQUIREMENT)

1) TAN DELTA ON ASSEMBLED MOTOR
2) NOISE SPECTRUM
3) LOCKED ROTOR TEST AS PER JEC-37
4) IP55 II NUMERAL
5) PRESSURISATION TEST
6) RETARDATION TEST etc.
 VFD INDUCTION MOTORS
ALSO CALLED VVVF THAT IS VARIABLE VOLATGE VARIABLE
FREQUENCY DRIVES
TYPES
1) CONSTANT POWER (V CONSTANT, F VARIED)
2) CONSTANT TORQUE (V/F IS KEPT CONSTANT)

ADVANTAGES

1) Eliminate Inefficient Mechanical System

2) Lower Stress On System
3) Lower Stress On Motor
4) Four Quadrant Operation
5) Step-less Control For Wide Speed Range
6) Efficient Operation( Low Energy Losses)
 DESIGN FEATURES OF AC MACHINES

LOW NOISE
• MAGNETIC NOISE MINIMISED BY
– APPROPRIATE SELECTION OF SLOT COMBINATION
– SKEWING OF STATOR/ROTOR SLOTS
– USE OF MAGNETIC PUTTY ON STATOR SLOT OPENING

• AERODYNAMIC NOISE MINIMISED BY

– STREAMLINED AIRFLOW PASSAGES
– LOW NOISE PROFILED FANS

• STRUCTURE BORNE NOISE

– NOISE ABSORBING MATERIALS ON THE JOINT FACES

• USE OF SILENCERS
 DESIGN FEATURES OF AC MACHINES

LOW VIBRATION
• DYNAMIC BALANCING OF ROTORS TO GRADE G-2.5 OF
ISO-1940 TO ACHIEVE LOW BEARING VIBRATIONS

• HIGH SPEED FLEXIBLE ROTORS BALANCED AT RATED

SPEED TO EVEN FINER GRADES TO ACHIEVE LOW
SHAFT VIBRATIONS

• VIBRATION LEVELS COMPLY TO CATAGORY ‘GOOD’ OF

ISO-10816
 DESIGN FEATURES OF AC MACHINES

BEARING INSULATION
• NDE BEARING INSULATED IF SHAFT VOLTAGE > 350
mV FOR MEDIUM RANGE MOTORS

• NDE BEARING INSULATED FOR ALL LARGE RANGE

MOTORS

• BOTH DE & NDE BEARINGS ARE INSULATED FOR

VFD MOTORS
 DESIGN FEATURES OF AC MACHINES

DESIGN CONSIDERATIONS

• LOAD DETAILS
• VARIATION IN SUPPLY VOLTAGE
• LOCKED ROTOR WITHSTAND TIME
• THERMAL WITHSTAND CHARACTERISTICS
• FREQUENCY OF STARTING
• VOLTAGE DIP DURING STARTING
 LOAD DETAILS
• LOAD TORQUE vs SPEED CURVE

• LOAD INERTIA VALUE

• TYPE OF COUPLING &

ITS DETAILS
 VARIATION IN SUPPLY VOLTAGE

• MOST COMMON VALUES ARE IN THE RANGE 5% TO ±10%

• STARTING & PULLOUT TORQUE VARIES AS (VOLTAGE) 2

• STARTING CURRENT DEPENDS ON VOLTAGE

• DURING RUNNING VARIATION EFFECTS MOTOR STABLE

OPERATION, CURRENT, TEMPERATURE RISE, EFFICIENCY
ETC.
 THERMAL WITHSTAND CURVES
TIME(SEC.)
10000
LOCKED ROTOR CURRENT = 500% FLC

FULL LOAD CURRENT = 742.0 AMPS

LOCKED ROTOR WITHSTAND TIMES :

HOT = 20.0 SEC
COLD = 38.0 SEC
• SAFE LOADING LIMITS & ITS
DURATION
1000
• SETTING OF LOCKED ROTOR
RELAY

• EFFECT ON MOTOR WINDING

INSUATION

• SPEED SWITCH FOR HIGH

INERTIA DRIVES 100

10
0 1 2 3 4 5 6 7
CURRENT (P.U.)
 FREQUENCY OF STARTING

• NORMAL VALUE IS 1 HOT, 2 COLD, 3 EQUALLY SPACED

STARTS PER HOUR

• DEPENDS ON TEMPERATURE RISE OF STATOR / ROTOR

WINDING PER START

• STRESSES DURING STARTING & INSULATION LIFE

• NOT MUCH CONCERN FOR SLIP RING & VFD CAGE MOTORS
 VOLTAGE DIP DURING STARTING

• VOLTAGE DIP DUE TO HIGH STARTING CURRENTS AT DOL

• EFFECT ON OTHER MOTORS / EQUIPMENTS NEARBY

• VOLTAGE DIP SHOULD NOT EXCEED MUCH TO KEEP THE

INPUT VOLTAGE AT MOTOR TERMINALS  MINIMUM
STARTING VOLTAGE

• PULL OUT TORQUE SHOULD BE  205% FLT FOR MOTOR

SMOOTH RUNNING EVEN AT 70% VOLTAGE FOR SOME
TIME
THANKS