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FMDS0517
FMDS0517
Table of Contents
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5-17 Motors and Adjustable Speed Drives
Page 2 FM Global Property Loss Prevention Data Sheets
List of Figures
Fig. 1. Typical motor protection scheme ....................................................................................................... 7
Fig. 2. Comprehensive microprocessor based motor protection system ...................................................... 8
Fig. 3. Typical adjustable speed drive protection scheme ............................................................................ 9
Fig. 4. Simplified diagram of the electrical system for a GMD motor (not showing excitation transformer) . 27
List of Tables
Table 1. Protection for Motor Bearings ........................................................................................................... 3
Table 2. Protection for Induction Motors ........................................................................................................ 4
Table 3. Protection for Synchronous Motors .................................................................................................. 5
Table 4. Protection for DC Motors .................................................................................................................. 5
Table 4a. Protection for Adjustable Speed Drives (Input Transformer) .......................................................... 6
Table 4b. Protection for Adjustable Speed Drives (Power Electronics) ......................................................... 6
Table 5. Recommended Maximum Voltages for Overvoltage Testing .......................................................... 13
Table 6a: AC Induction Motors ..................................................................................................................... 14
Table 6b: AC synchronous motors (round rotor and salient rotor) ............................................................... 15
Table 6c: DC Motors ..................................................................................................................................... 16
Table 7. Visual Indications and Likely Causes ............................................................................................. 18
Table 7. Visual Indications and Likely Causes (cont’d) ................................................................................ 19
Table 8. Motor Tests ...................................................................................................................................... 20
Table 8. Motor Tests (cont’d) ........................................................ 21 ........................................................ 22
Table 9. DC Motors Loss History, 1993 to 2013 .......................................................................................... 29
Table 10. Induction Motors Loss History, 1993 to 2013 .............................................................................. 29
Table 11. Synchronous Motors Loss History, 1993 to 2013 ........................................................................ 29
Table 12. IEEE Reliability Survey ................................................................................................................ 30
1.0 SCOPE
This data sheet provides operation, testing, maintenance, and protection guidelines for large, form wound,
alternating current (AC) and direct current (DC) motors. In general, this encompasses motors larger than 600
hp (440 kW) with voltage ratings of 2,300 V and higher.
1.1 Changes
July 2020. Interim revision. Updated routine spare guidance for gearless mill drives and provided additional
clarification on sparing in Section 2 and 3.
2.1 Protection
2.1.1 Where combustible construction or occupancy is present, provide sprinkler protection in accordance
with the applicable FM Global data sheet, including, but not limited to, the following:
A. Provide cable protection per Data Sheet 5-31, Cables and Bus Bars.
B. Install and protect the storage of lubricating oils per Data Sheet 7-88, Ignitable Liquid Storage Tanks.
C. Protect switch rooms per Data Sheet 5-19, Switchgear and Circuit Breakers.
D. Protect transformers per Data Sheet 5-4, Transformers.
2.1.2 Provide an FM Approved, fixed, automatic carbon dioxide extinguishing system for adjustable speed
motor drives in critical applications. Design the system to flood the drive enclosure or room. Install smoke
detectors inside the enclosure to actuate the system. Ensure actuation de-energizes the drives and sounds
an alarm at a constantly attended location. Design extinguishing systems in accordance with Data Sheets 4-0,
Special Protection Systems, and 4-11N, Carbon Dioxide Extinguishing Systems, as appropriate.
2.1.3 Provide FM Approved wheeled portable carbon dioxide or dry chemical extinguishers at all manned
and unmanned locations. Refer to Data Sheet 4-5, Portable Extinguishers, to determine effective sizes and
locations for the extinguishers. Protect extinguishers located outside against freezing.
2.2 Mechanical
2.2.1 Provide protection for motor bearings in accordance with Table 1. Arrange these protective devices to
alarm first and then to trip the motor if the condition gets worse and no corrective action is taken.
2.3 Electrical
2.3.1 Provide electrical protection in accordance with Tables 2, 3, 4, 4a, and 4b depending on the type of
motor and whether an adjustable speed drive is used.
Tables 5a and 5b show additional protection for adjustable speed drives. They list protection requirements
for the adjustable speed drive and the isolation transformer. Ensure the motor itself is still provided with the
protection devices recommended in Tables 2, 3, and 4.
The arrangement of these electrical protective devices is illustrated in Figures 1, 2, and 3.
2.3.2.2 Protect the cycloconverter drive supplying the wrap-around motor in accordance with Tables 4a and
4b.
2.3.2.3 Provide the following monitoring functions for cooling systems in wrap-around motors. Arrange each
function to give an alarm warning for low or high limits.
A. Cooling water flow monitors or switches for heat exchangers
B. Cooling air temperature monitors
C. Cooling air humidity monitor to protect against moisture condensation
2.3.2.4 Provide online partial discharge monitoring devices for gearless mill drives. Perform quarterly partial
discharge measurement for diagnostic analysis.
2.3.3 Provide surge protection in accordance with Data Sheet 5-11, Lightning and Surge Protection for
Electrical Systems.
2.4.1 In-Service
2.4.1.1. Start, load, and operate all motors and drives per manufacturer’s nameplate rating and instructions.
2.4.1.2. Provide all motors and drives with the proper enclosure and insulation type for the prevailing
condition.
2.4.1.3. Keep motor bearings clean and cool. Lubricate bearings using only the manufacturer’s recommended
lubrication.
2.4.1.4. Protect motor bearings against stray or eddy currents using either bearing seat/pedestal insulation
or shaft grounding.
2.4.1.5. Operate adjustable speed drives in a cool environment. If this is not practical, provide some means
of cooling, such as water-cooling or air conditioning. Continuous operation with open cabinet doors is not
an acceptable alternative.
2.4.1.6 For gearless mill drives, log operational data with a time-stamp to record any critical events.
2.4.5 Testing
2.4.5.1 Tables 6a, 6b, and 6c list the electrical and mechanical tests that are typically performed at motor
dismantles and inspections. The number of tests will depend on condition-monitoring data, results of routine
inspections, operating experience, and failure history.
2.4.5.2 In addition to the tests listed in Tables 6a, 6b, and 6c, perform thermographic surveys of motors at
least once a year. Check the bearings, motor frame, motor terminal box, surge capacitors, cables, motor
controller, and adjustable speed drive for overheating.
2.4.5.3 If online vibration monitoring is not provided, perform vibration measurements of the shaft and bearings
at least once a month.
2.4.5.4 Test and maintain electrical protective devices (surge arrestors, fuses, circuit breakers and relays)
in accordance with Data Sheet 5-19, Switchgear and Circuit Breakers.
of detecting a sudden rise in leakage current because capacitive charging current will be constant during
the test. This increases the chances of detecting defective insulation and aborting the test before the insulation
is punctured.
2.4.6.6 An alternative is to increase the applied voltage in 1 kV steps and to measure the leakage current
after 1 minute. This test is less sensitive because capacitive charging current may mask a sudden rise in
leakage current.
2.4.6.7 The recommended maximum voltages for overvoltage testing are provided in Table 5:
2.4.6.8 Do not DC overvoltage test a motor close to the end of its design life. Refurbish or replace the motor.
2.4.6.9 Surge comparison testing of the stator winding is also a potentially destructive test. A high voltage
is applied to check the integrity of turn insulation. This test provides little diagnostic information. Failure of turn
insulation will require the stator bar to be cut out and repaired. Only perform surge comparison testing after
winding repair, rewinds, or when there is a reason to suspect a problem with the turn insulation.
2.5.2 Sparing
Sparing can be a mitigation strategy to reduce the downtime caused by gearless mill drive (GMD), also called
“wrap-around” or “annular synchronous motors,” breakdowns depending on the type, compatibility, availability,
fitness for the intended service, and viability of the sparing. For general sparing guidance, see Data Sheet
9-0, Asset Integrity.
Bearing failure due to fatigue also can result from excessive loads or failure to replace bearings when they
have reached the end of their lives.
Shaft currents also can cause damage to the bearings. Shaft currents flow to ground through the bearing.
This creates arcing at the bearing surface. The bearing surface becomes pitted and this affects the oil flow,
eventually leading to overheating and failure of the bearing.
Shaft currents are created by harmonics, poor shaft grounding, and faulty bearing pedestal grounding.
Misalignment between the motor and driven object can also cause bearing damage.
Bearing failure can cause rubbing damage to the rotating and stationary parts of the motor. Fortunately,
bearing failures tend to develop slowly and will provide several indications that failure is imminent. These
indications include an increase in bearing noise, vibration, or temperature. Bearing lubrication oil analysis also
will provide early warning of bearing problems.
H. Contamination. Motors operating in environments with fly ash, coal dust, solvents, acids, cement dust,
oil, and other contaminants will be susceptible to electrical tracking, erosion and chemical attack. This
is especially true for open ventilated machines where cooling air is taken directly from the surrounding
environment.
I. End winding vibration. Stator end windings hang outside the core and need to be properly supported;
otherwise, they can vibrate and abrade the insulation, eventually resulting in failure.
3.3.3 Overheating
Overheating was discussed in the previous section as a cause of thermal deterioration of winding insulation.
The following is additional detail on the causes of overheating:
A. Operating at lower than rated voltage produces higher currents and increased heat losses (I2R) in the
motor winding. This generates heat beyond the motor’s cooling capacity.
B. Mechanical failures interfering with the rotation of motors, such as jammed impellers on driven pumps
or fans, damaged seals on driven pumps, misalignment and bearing failure, can interfere with the rotation
of motors. This can cause the motor to draw more current and, in the worse case, locked rotor conditions
can result which will quickly overheat the motor.
C. Poor brush pressure, improper brush material, or improper brush contact with the commutator or slip
ring can cause the brush to overheat. Overheating can lead to commutator or slip ring damage. This will
lead to a short circuit or an open circuit in the armature winding of DC motors or the field winding of
synchronous motors.
E. Operating motors at higher than rated load results in higher currents and increased losses in the winding.
If the overload is large enough, the motor may fail to start or accelerate, or it may stall.
F. Lack of adequate time between starts can overheat the windings and reduce their insulation life. In
addition, this heat may crack the rotor bars in squirrel-cage motors and the damper windings in
synchronous motors.
G. Duty cycles involving rapid repetitive starting, plugging, jogging, and reversal will cause cumulative
heating of the motor.
H. Loss of ventilation prevents heat removal from the motor. Ventilation loss is commonly caused by
restricted air ventilation paths. High ambient (room) temperature, above 104°F (40°C), also can lead to
overheating.
discharge activity beyond the motor (e.g., in connected cables, ground leads, and buses). Because
electromagnetic interference testing requires access to the motor ground lead, however, this test may not
be able to be carried out on all motors.
3.4.3.7 Air Gap Flux Probes
Air gap flux probes are applied in large synchronous motors. The probes are small search coils permanently
installed in the air gap of the motors to measure rotor slot leakage flux. The waveform from the flux probes
is used to identify shorted turns in the rotor winding. Readings from the air gap flux probes are taken
approximately once a year to monitor rotor winding deterioration. Readings are also taken whenever bearing
vibrations increase to determine if the cause of the increased vibration is due to shorted rotor turns.
3.4.4 Condition-monitoring systems are not able to detect all failure modes. Therefore, it is important to take
the opportunity to inspect the machine any time it is opened for other purposes and not to rely wholly on
condition-monitoring data. It is also important to continue with routine offline motor testing to complement
condition-monitoring results.
Circuit breaker
Filters
compensation
Cyclo-converter
transformers
Cyclo-converter
Gearless SM
mill drive
Excitation Excitation
converter
Fig. 4. Simplified diagram of the electrical system for a GMD motor (not showing excitation transformer)
Because the GMD is used in a dusty environment, a dust shield with a metal to Teflon seal is provided between
the rotating mill body and the stator frame to keep dust and water out of the motor windings.
4.0 REFERENCES
4.1 FM Global
Data Sheet 4-0, Special Protection Systems
Data Sheet 4-11N, Carbon Dioxide Extinguishing Systems
Data Sheet 5-11, Lightning and Surge Protection for Electrical Systems
Data Sheet 5-19, Switchgear and Circuit Breakers
Data Sheet 5-20, Electrical Testing
Data Sheet 5-31, Cables and Bus Bars
4.2 Others
Institute of Electrical and Electronics Engineers (IEEE). Guide for AC Motor Protection. IEEE C37.96-2012
Institute of Electrical and Electronics Engineers (IEEE). Guide for Diagnostic Field Testing of Electric Power
Apparatus - Electrical Machinery. IEEE 62.2-2004.
Institute of Electrical and Electronics Engineers (IEEE). Recommended Practice for Insulation Testing of AC
Electric Machinery (2300V and Above) With High Direct Voltage. IEEE C95-2002.
National Electrical Manufacturers Association (NEMA). Motors and Generators. NEMA MG 1-2011.
Commutator: Cylindrical ring or disk assembly of conducting bars mounted on the rotor (armature) of
direct-current motors. The conducting bars are each insulated with an exposed surface for contact with
current-collecting brushes.
Compound-Wound Motor: Direct-current motor with two field windings: one, usually the predominating field,
is connected in parallel with the armature circuit; the other is connected in series with the armature circuit.
Damper Winding Amortisseur Winding): A winding consisting of several conducting bars that are short-
circuited at the ends with a conducting end ring or plates. These conductors are distributed on the field poles
of a synchronous machine to suppress pulsating changes in magnitude or position of the magnetic field
linking the poles.
Duty: Requirement of electrical service defining the degree of regularity of the load. Heavy duty is often used
to denote an application requiring high locked-rotor torque and having high intermittent overloads. Similarly,
light duty often describes an application requiring very little locked-rotor torque and little overload capacity.
Duty, Continuous: Requirement of service that demands operation at a substantially constant load for an
indefinite period of time.
Duty, Intermittent: Load changes regularly or irregularly with time.
Efficiency: Ratio of useful power output to the total power input.
Electrically Reversible Motor: Can be reversed by changing the external connections even while the motor
is running. If, while the motor is running at full speed in one direction, the connections suddenly change to the
opposite direction of rotation, the motor will stop, reverse, and resume full speed in the opposite direction.
A class of service where the motor is expected to perform this duty is often known as plugging service.
Field Coil (DC and AC salient pole): Suitably insulated winding to be mounted on a field pole to magnetize
it.
Field Winding (cylindrical rotor): Produces the main electromagnetic field of the motor.
Form Wound: As opposed to random-wound motors where the winding consists of round insulated magnet
wire randomly wound into the stator slot to form a coil, form-wound motors have pre-formed insulated stator
bars consisting of multiple conductor strands that are inserted into the stator slot to form a coil.
Frame: Supporting structure for the stator parts. In a DC motor it usually is part of the magnetic circuit; it
includes the poles only when they are an integral part of the frame.
Frozen Charge: When an ore grinding mill is shut down over a long period with a charge inside the mill,
the charge may solidify into a single mass. When the mill is started with a frozen charge, the charge will stick
to the mill shell and not cascade when it reaches the critical angle. In the worst case, the charge will stick
to the shell and be carried to the 180o angle and fall as a solid block.
IEEE Device Number: The number used to identify protection relays. Refer to ANSI/IEEE C37.2 “IEEE
Standard Electrical Power System Device Function Numbers” for additional detail.
Induction Motor: Converts electric power at the primary circuit into a mechanical power. The secondary circuit
short-circuits or closes through a suitable circuit and carries induced current.
Rotor: Rotating member of a machine.
Salient Pole: Type of field pole that projects toward the armature.
Series-Wound Motor: Direct-current motor in which the field and armature circuits are connected in series.
Service Factor: Multiplier that, when applied to the rated power, indicates a permissible power loading that
may be carried under the conditions specified for the service factor.
Shunt-Wound Motor: A direct-current motor in which the field circuit and armature circuit are connected in
parallel.
Squirrel-Cage Induction Motor: Involves a secondary circuit consisting of a squirrel-cage winding suitably
portioned in slots in the secondary core.
Squirrel-Cage Winding: Permanently short-circuited winding, usually uninsulated (chiefly used in induction
machines), having its conductors uniformly distributed around the periphery of the machine and joined by
continuous end rings.
Stator: The stator is the portion of a machine that contains the stationary parts of the magnetic circuit with
their associated windings.
Synchronous Motor: Average speed of normal motor operation is exactly proportional to the frequency of
the system to which it is connected. It transforms electric power from an AC system into mechanical power.
Synchronous motors usually have DC field excitation.
Wound-Rotor Induction Motor: Secondary circuit of the motor consists of a polyphase winding or coils whose
terminals are either short-circuited or closed through an adjustable resistance.
A.2 Adjustable Speed Drive Glossary: Terms Defined in Accordance with IEEE P958
Adjustable Speed Drive: An electric drive system designed to adjust speed of a motor and its driven equipment
across a specified speed range.
Commutation: The transfer of the current from one converter switching branch to another.
Converter: An operative unit for electronic power conversion, comprising one or more electronic switching
devices and any associated components, such as transformers, filters, commutation aids, controls and
auxiliaries.
Current Limiting: An overload protection mechanism that limits the maximum output current to a preset value,
and automatically restores the output when the overload is removed.
Drive System: Combination of the power converter (controller), motor, and any motor mounted auxiliary
devices; also equipment for converting available power into mechanical power suitable to operate a machine.
Efficiency: The ratio of load power to the total line power, including the contribution of all harmonics.
Harmonics: A sinusoidal component of a periodic wave or quantity having a frequency that is an integral
multiple of the fundamental frequency.
Inverter: A machine, device or system that changes DC power to AC power.
Power System: The electric power sources, conductors, and equipment required to supply electric power.
Source: The electrical network to which a drive is connected.
Speed Range: All the speeds that can be obtained in a stable manner by action of a part (or parts) of the
control equipment covering the performance of the motor. The speed range is generally expressed as the ratio
of the maximum to the minimum operating speed.
Stability: The ability of a drive to operate a motor at constant speed (under varying load), without “hunting”
(alternately speeding up and slowing down). It is related to both the characteristics of the load being driven and
electrical time constants in drive regulator circuits.
Synchronous Speed: The speed of rotation of the magnetic flux, produced by or linking the primary winding.
June 1976. Data Sheet 5-17, Large Electric Motors, first issued.
overload device must be selected to trip at no more than (a) 125% of rated full load current for motors with
a service factor not less than 1.15, and (b) 115% of full load current for all other motors.
A. One overcurrent relay for failure to accelerate to rated speed protection, and a second overcurrent
relay supervised by a zero speed switch to provide locked rotor protection. During startup, the speed switch
disengages the locked rotor protection, leaving protection to the failure to accelerate relay. After the motor
is up to speed, the locked rotor protection is engaged.
B. A relay with independent adjustments for failure-to-accelerate and locked-rotor characteristics.
C. A distance relay and a timer.
APPENDIX D BIBLIOGRAPHY
Fitzgerald, E. and Charles Fingsley, Jr., Stephen D. Umans. Electric Machinery. 4th ed. McGraw-Hill Book
Company, New York, 1983.
GE Motors. AC Motor Selection and Application Guide. (GET-6812a, 6M 2/90). General Electric Company,
Fort Wayne, Indiana.
Smeaton, Robert W. Motor Application and Maintenance Handbook, McGraw-Hill Book Company, New York,
1969.
Stone, Greg, et.al. Electrical Insulation for Rotating Machines, Wiley-IEEE Press, 2003.
Toliyat, Hamid and Gerald Kliman. Handbook of Electric Motors. 2nd Ed. Marcel Dekker Inc, 2004.