Role of cooling on large MV Induction motor design output

The basic formula used for induction motor design is based on the following equation,

Motor output = D2L, where

D = Diameter of rotor of the motor

L = Motor core length

However, how much output we shall be able to extract from a particular wound stator &
rotor core pack depends primarily on how efficiently we are able to cool the motor. The
purpose of this paper is to evaluate a data, how the motor output varies, when same D 2L
design for a particular voltage & pole is operated with different cooling enclosure.

When a motor is run on full load, heat is generated due to primarily stator and rotor copper
losses & Iron loss etc. Depending upon the motor enclosure, some cooling method is
applied on the motor, which cool the heat generated due to the above losses. The output
that can be extracted from a wound particular core pack at a particular speed depends on
how efficiently the heat is extracted from a motor. Better is the cooling efficiency, higher is
the motor output. Considering the present day industry practice, motor steady state
winding temperature is limited to 1200C, measured by resistance method. Due to
competitive market in motor selling business, manufacturers design a motor for a particular
application with a maximum of (5-10)0C margin in motor operating temperature.

In MV motor design, based on cooling system, there are 5 variety of motors used across the
globe. These are classified as follows:

1. TEFC (Totally enclosed, Fan cooled) with IC4A1A1 method of cooling

2. TETV (Totally enclosed, Tube ventilated) with IC5A1A1 method of cooling
3. CACA (Closed Air circuit, Air cooled) with IC6A1A1 method of cooling
4. CACW (Closed Air circuit, Water cooled) with IC8A1W7 method of cooling
5. ODP (IP 22/23/24)

Although limiting the motor temperature is not the only criteria for motor design, but
considered as most important. For the sake of simplicity, in this discussion, let us keep aside
other important design parameters like motor starting and maximum torque, starting
current etc. We shall try to figure out in the simplest way on approximate estimation of
motor output rating, when same D2L is enclosed with different cooling system.

TEFC In a TEFC motor, motor core pack is enclosed in a ribbed steel frame with inference
fitting. Motor is with closed type construction with no access of external air and water
inside and the motor enclosure is cooled with a cooling fan, generally fitted at the opposite
end of motor shaft. The heat that is produced by motor inside, is transmitted to motor
surface by conduction method and motor surface temperature is heated up, which is cooled
down by an efficient fan guided by a fan cover.

TETV In a TETV motor, frame has in-built tubes all around the stator core for cooling
purpose. The frame has got internal ribs of about (25-40) mm height and wound stator core
pack is fitted on the ribs. Motor has got 2 nos. fan - one internal and one external. The
internal fan extracts internal hot air from inside and throws same on to the tubes, thus
making it hot. The external fan delivers cold external air through the tubes and thus cools
the heated tubes.

CACA In a CACA motor, the frame top is generally of open type & rectangular in shape and
an air to air heat exchanger consisting of MS/Stainless steel cooling tubes are mounted on it.
There are 2 nos. fan - one internal and one external and the internal fan extracts hot air from
inside motor and throws same to the heat exchanger and thus heating the tubes. The
external fan throws cold external air through the tubes and thus cools the hot tubes.

CACW Construction of stator frame is similar to CACA and there is only one internal fan,
which extracts hot internal air from inside and throws same to the tubes of water cooler on
the top. Instead of air to air heat exchanger at the top of frame, an air to water cooler is
mounted with 2 openings, one for entry of water at atmosphere temperature (35 0C) & the
other for the exit of hot water. Generally, pressure gauge & flow meter is mounted on the
heat exchanger for controlling the water flow as per design parameters.
ODP This is open type motor with two openings in the frame one for external cold air
entry and the other for the hot air exit. An internal fan mounted on shaft throws hot air
from inside of motor, thus creating vacuum at the other opening, allowing cold air to enter
motor.

For each variety of motor enclosure detailed above, maximum output is calculated at a load,
when the motor winding temperature stabilizes at (110-115)0C, considering cl-B
temperature rise limit.

Now, we want to find out how the motor output varies with change of motor enclosure. I
would like to share my experience on this issue, when same D2L with wound stator and
copper cage rotor is housed in different enclosures. As a typical case, let us consider a
motor core pack with 675mm outer diameter and 525mm core length in 4P design.

If, we consider the output achieved in TEFC frame is X KW, then the same D 2L will approx.
deliver the following output when run in different enclosures.

TEFC X KW
TETV (1.2 1.3)X KW
CACA 1.4 1.5)X KW
CACW (1.5 - 1.6)X KW
ODP (1.5 1.6)X KW

Due to standardization purpose and also to reduce manufacturing cost, manufacturers

normally use the same basic electric design using a particular D 2L for a particular voltage &
pole and the same is housed in different enclosure for achieving different output. However,
changes are always done in stator winding to meet the other technical requirements of
motor application. In this evaluation, we have considered identical core pack design for all
the above variety of enclosure.