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Safety of Ex nA, Ex e and Class I

Division 2 motors
ABB Group
April 1, 2011 | Slide 1

Which international standards are addressing the sparking


phenomena?

Standard with verification requirements

ABB Group
April 1, 2011 | Slide 2

Only the latest editions of the IEC


and EN standards specify the
problem!
Many countries implement the IECstandards into their national
standards.
Various countries define the edition
of the standards by internal rules
=> Many countries do not follow
contemporary the latest
requirements and therefore they are
not addressing the sparking
phenomena today.

Which international standards are addressing the


sparking phenomena?

ABB Group
April 1, 2011 | Slide 3

History of accident in the


U.K.

ABB Group
April 1, 2011 | Slide 4

History of accidents involving electric motors in the UK

Actions taken by Authorities

Initiated several studies

Based on studies, they gave series of


recommendation to users mainly in the UK

The development of international standards


were initiated

Actions taken by End Users

Required gas environment testing in practice


and experience from the tests

Comparison between different practices to


fulfill the standard requirements

Inspection and overhaul of electric motors on


field

Actions taken by standardization


committees

ABB Group
April 1, 2011 | Slide 5

ENV 50269

Risk assessment requirements implemented


to IEC/EN standards

Where and when sparking


can occur

ABB Group
April 1, 2011 | Slide 6

Stator sparking in respect of safety

ABB Group
April 1, 2011 | Slide 7

When and Where it can occur?

All the time when the motor is


running

Partial discharges (PD) at the


surface of the winding

Partial discharges at the surfaces of


connection cables
Main reasons for stator sparking

High voltage and improper stress


grading

Inadequate clearance distances

Direct contact between ground


enclosure and high voltage cable

Heating wires mounted on coil


overhangs

Aging of the windings

Voltage transients

Dirty surfaces of windings

Rotor sparking in respect of safety

When and Where can it occur?


During the first cycles when motors
are started
Between rotor bars and rotor core
Close to end of rotor core packs or
close to the first radial cooling ducts
Main reasons for rotor sparking
Leakage current from rotor bar to rotor
core is switching due to possible
movements of the rotor bars in the
slots

ABB Group
April 1, 2011 | Slide 8

Circulating currents

Where and When can it occur?


Between separate parts of enclosures
When motor magnetized and running
Over-voltages
Main reasons for circulating current
Parts get charges due to magnetic flux
created by the stator
Parts are not equip-potential bonded
and they floating on own potential
Improper grounding
Equip-potential cables are
disconnected

ABB Group
April 1, 2011 | Slide 9

When risk assessment is applicable?

Note, waiver from some duty


types where the motor is
started once per week or
less.

Non-sparking motors (IEC 60079-15:2005 and EN 60079-15:2005)

Increased safety motors (IEC 60079-7:2006 and EN 60079-7:2007)


ABB Group
April 1, 2011 | Slide 11

Stator risk assessment


Increased safety motors

ABB Group
April 1, 2011 | Slide 12

Stator risk assessment


Non-sparking motors
Risk assessments for the Ex nA stator
constructions shall be if the sum of
risk factors is greater than 6:

Stator design shall be pass the required


non-sparking tests, or

Motor shall be equipped with a provision


pre-start ventilation (Note! operator
needs to make decision to use it or not
based their possibility accept the risk)

Note, the table will be moved to IEC 60079-14 in the future, and the stator
gas testing will be compulsory for all random-wound high-voltage stators
and all high-voltage form-wound stators in gas groups IIC and IIB, as well as
in gas group IIA if the nominal voltage is greater than 6.6kV
ABB Group
April 1, 2011 | Slide 13

Rotor risk assessment

Non-sparking motors (IEC 60079-15:2005


and EN 60079-15:2005)

Special measures shall be applied if the sum


of risk factors is greater than 5
ABB Group
April 1, 2011 | Slide 14

Increased safety motors (IEC 600797:2006 and EN 60079-7:2007)

Special measures shall be applied if the sum


of risk factors is greater than 6

Tests to verify that the


designs are non-sparking
per IEC 60079 standards

ABB Group
April 1, 2011 | Slide 15

Stator test
Sinusoidal voltage test

ABB Group
April 1, 2011 | Slide 16

Sinusoidal voltage test continuous


operation

Insulation systems and connection


cables shall be tested in an explosive
gas mixture comprised of (21 5) %
hydrogen-in-air or (7,8 1) % ethylenein-air, v/v

U = A sinusoidal voltage of 1,5 times


the rated r.m.s. line voltage for 3 min

The maximum rate of voltage rise shall


be 0,5 kV/s

In this test will be tested insulation


between

Phase and earth

Phase and other phases

Stator test
Voltage impulses test

ABB Group
April 1, 2011 | Slide 17

Voltage impulses test transient conditions

Insulation systems and connection cables


shall be tested in an explosive gas mixture
comprised of (21 5) % hydrogen-in-air or
(7,8 1) % ethylene-in-air, v/v

U = 10 voltage impulses of three times peak


phase voltage with
a tolerance of 3 %

A voltage rise time between 0,2 s and 0,5


s

A time to half value which is at least 20 s


but normally not exceeding 30 s

Electrical connection same as a sinusoidal


voltage test

In this test will be tested insulation between

Phase and earth

Phase and other phases

Rotor test

Aging

ABB Group
April 1, 2011 | Slide 18

The rotor cage shall be subject to an


ageing process comprising a minimum
of five locked rotor tests

The maximum temperature of the cage


shall cycle between the maximum
design temperature and less than 70C

The applied voltage shall be not less


than 50 % of the rated voltage

Rotor test

Tests

ABB Group
April 1, 2011 | Slide 19

The same gas mixtures as for stator testing

Motors shall be subjected to 10 direct-on-line uncoupled


starts or 10 locked rotor tests. These tests shall have a
duration of at least 1 s

No explosion shall occur

During the tests, the terminal voltage shall not fall below 90
% of the rated voltage. The concentration of hydrogen or
ethylene shall be confirmed after each test

Scenarios to users and


their pros and cons

ABB Group
April 1, 2011 | Slide 20

Three scenarios for end users

ABB Group
April 1, 2011 | Slide 21

1.

To perform Risk Assessment for each case together with


Manufacturer and keep fingers crossed, or

2.

To have a Provision for Pre-Purging if Risk factors limits


are exceeded, or

3.

To require manufacturers to carry out gas testing and


provide certification based on that

Scenario 1
To perform risk assessment for each case
Easiest and most attractive procedure from Manufacturer, but
in practice its brings couple of issues

In most of the cases, the risk factor limits are exceeded, and
special measures are needed.

Lack of information flow

Effective co-operation is needed between End User and


Manufacturer during the motor design phase (through
mech.vendor and contractor)

All information is not typically available at that time

Changing specification

Varying conditions during the machines life time

ABB Group
April 1, 2011 | Slide 22

Risk assessment results might change many times during


tendering
Certificate will have limitation of use per risk assessment
results

Scenario 2
Provision for Pre-Purging when Risk Factor Limits Exceeded
Another easy and economical solution for
manufacturers

ABB Group
April 1, 2011 | Slide 23

Manufacturer provides flanges and End User / Operator


takes the responsibility to decide to use them or not

Safety engineers typically require purging if the risks are


indicated

If pre-purging is selected by end user

Does NOT protect against stator partial discharges,


which can occur all the time. Thats the reason why IEC
60079-7:2006 requires stator testing for all motors
above 1kV

10 to 60min delay in the start

Additional investments to purge control device, piping


and air compressor

Additional cost for operator to run air compressor

Overall reliability is reduced due to additional


components

Scenario 3
Gas testing and Certification
To required that Gas testing is carried out for Rotor &
Stator is probably the best way for End Users &
Operators

ABB Group
April 1, 2011 | Slide 24

No ones responsibility on end user of motor safety

To get confirmation that the design is non-sparking per


international standards

Not to have any limitations of the use of a need to review


risk assessment if factors are changing e.g. starting
frequency or maintenance strategy

Longer life-time for stator insulation due to no surface


discharges

ABB approach

ABB Group
April 1, 2011 | Slide 25

The required gas tests are performed for most of


HV motors
The gas test covers

LV Motors: M3_P motors produced in Vaasa


(rotor test)

Induction Machines: HXR, AMA, AMI, M3


produced in Helsinki or Shanghai (stator &
rotor test)

Synchronous Machines: AMG and AMZ


produced in Helsinki (stator test)

Results of the test

All rotor test passed (LV & HV)

Stator test passed (HV)

13.2 kV with IIC gases

15 kV with IIA and IIB gases

Other Ex nA motors which are not covered


by the type testing are equipped with a
provision for pre-start purging
ABB Group
April 1, 2011 | Slide 26

Purge control units are always available as


an option

Benefits of gas tested motor for Operators / End Users

ABB Group
April 1, 2011 | Slide 27

Streamlining the risk assessment process


(not need of risk factor calculations)

Re-inforce the insulation system increase the


time life of products

The alternative to testing and certification


involves equipping the motor with provision
for pre-purging

Investment in a higher capacity air


compressor, piping, and a purge control
unit

Requires an additional operation


purging every time the motor is started

Benefits of gas tested motor for Operators / End Users

Benefits of the ABB approach therefore


include reduced

Danger is often marked with black and


yellow.Thats why our machines are blue!

ABB Group
April 1, 2011 | Slide 28

Initial capital expenditure

Lower operating costs

Faster starting

Higher reliability is improved as no


additional components are required

Most importantly, ABBs certified motors


offer proven safety, as testing represents
the only way to verify that equipment is
really safe

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