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Wound Rotor To Induction Motor and VFD Conversion Case Study PDF
Wound Rotor To Induction Motor and VFD Conversion Case Study PDF
I. I NTRODUCTION
Manuscript received March 30, 2011; accepted December 31, 2011. Date of
publication March 6, 2013; date of current version May 15, 2013. Paper 2011- III. W HAT I S A WR M OTOR ?
PPIC-100, presented at the 2011 IEEE Pulp and Paper Industry Conference,
Nashville, TN, USA, June 19–23, and approved for publication in the IEEE The WR motor is an induction motor where the rotor circuit
T RANSACTIONS ON I NDUSTRY A PPLICATIONS by the Pulp and Paper Indus-
try Committee of the IEEE Industry Applications Society. is terminated in slip rings to which external impedances can be
The author is with ABB Process Automation Pulp and Paper, Greenville, SC connected (see Fig. 2). The stator is essentially the same as is
29680 USA (e-mail: michael.kozlowski@us.abb.com). used in any standard squirrel cage motor. By changing the exter-
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org. nal impedance connected in the rotor circuit, the speed/current
Digital Object Identifier 10.1109/TIA.2013.2251594 and speed/torque curves of the induction motor can be altered.
Fig. 2. Typical WR motor for use in the trolley motion of a woodyard portal
crane.
where
Fig. 5. NEMA MG1 table indicating WR motor breakdown torques of various
horsepowers and revolutions per minute [1]. HPnew raw horsepower required to produce the same
amount of torque as the existing WR motor;
We use (2) above to calculate the motor’s 100% torque. The
N nameplate base revolutions per minute of the new
next question to address is what breakdown torque do we use to
VFD motor; it is the same as the WR motor;
size the overload torque of the new motor?
Tq previously calculated (100%) torque of the WR
One source is the National Electric Manufacturing Asso-
motor in foot pounds.
ciation (NEMA) standards for WR motors, which indicate
that the minimum breakdown torque produced be 225% for a The new calculated motor horsepower is 279 hp. This may
100-hp 1800-r/min machine (see Fig. 5). These are considered seem to present a problem because the new motor is 280%
minimum breakdown torque values and can be adjusted up on larger than the original application. Most likely, the new induc-
a case-by-case basis to suit application requirements. tion motor will be smaller than the existing WR motor and can
Some vintage WR motor crane applications have been de- fit into the existing motor’s centerline shaft height.
signed to produce the 250%–300% breakdown torque. The In this example, we are intending to replace the WR motor
curves below are from a 1930’s produced motor. and resistor bank with a new motor and VFD, we can size
Referring to Fig. 6, the dotted horizontal line on top of the the motor and drive to accommodate a 200% overload for
crests of the speed torque curve(s) indicates motor maximum 60 s in order to accelerate its load. The new nameplate(s) of
peaks at 280% breakdown torque. Since the minimum as listed the ac system will have to indicate it is sized for 200% overload
by NEMA is 225% breakdown torque and the crane application for 60 s. The VFD is also required to be sized for the 200%
requires 280%, the quandary is what overload should we use for overload.
the application, i.e., 225% or 280%? As previously indicated, The next step is dividing the new calculated motor horse-
it is important to size the new motor’s overload requirements power by the overload rating (which is 200% or 2 per unit)
while keeping the original application in mind. In this case, for HPnew
a crane application, a maximum of 280% overload is selected. HPfinal = (4)
OL
Other applications such as pulpers or refiners may require less.
Since the WR motor is estimated to supply a maximum of where
280% per unit breakdown torque, the motor can then produce HPnew raw horsepower calculated to produce the same
2.80 ∗ 291 = 815 ft · lbs of torque to accelerate its load. Thus, amount of torque as the existing WR motor;
the ac VFD equivalent must be able to supply the same or more HPfinal 200% overload rating of the new motor in horse-
torque over the same speed range. power;
Next, the new ac VFD horsepower is to be calculated from OL overload rating in per unit, which is 2.
the required (overload) torque. Note that, since this is a retrofit The new horsepower is calculated as 280/2 = 140 hp.
situation and other connected equipment (gearboxes) may be Rounding up to the next standard horsepower and selecting a
utilized, a motor with the same revolution per minute should be 150-hp motor, the nameplate revolutions per minute will remain
selected, i.e., the same.
(2.8 × Tq ) × (N ) The end result is an application that will be 150 hp at 200%
HPnew = (3)
5252 overload. Comparing system torques, the WR motor system is
1224 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 49, NO. 3, MAY/JUNE 2013
Fig. 8. Woodyard portal crane, which was modernized with new VFD duty
motors.
Fig. 12. Hoist WR motor being removed during the modernization outage.
Fig. 11. Comparison of pre- and postmotor weights and shaft heights.
The mill performed the conversion from WR motor control to The drive system consisted of a dedicated regenerative drive
a regenerative VFD-based control system with an active front- for each motion, as each motion can be potentially in use at
end common bus unit during the third quarter of calendar year the same time, either consuming or regenerating energy. The
2009 (see Fig. 12). trolley and gantry drives powered multiple motors; thus, these
The new variable frequency duty motors were quoted to a respective VFDs output current is the sum of individual motor
drive system vendor as part of the portal crane drive system currents (see Fig. 13).
modernization project. The hoist and gantry motors were se-
lected by the mill to be of totally enclosed fan-cooled (TEFC)
B. Performance Measurement
cast iron construction with IEEE 841 [4] features. The trolley
motion motors were selected to be TEFC-laminated frame con- After the project was complete, the mill’s woodyard manager
struction in order to keep the trolley weight down as much as permitted the author access to the drive system site engineer,
possible, since the trolley motion has to start and stop with more who provided the portal crane’s “postmodernization” VFD
rapidity than either hoist or gantry motions. Laminated frame current feedback parameters. The engineer provided individual
motors can be 15%–20% lighter than comparable cast iron drive current feedback samples taken at 10-ms intervals, which
construction motors and can also radiate heat more efficiently he felt would provide a good resolution for observation of
since the motor frame is active material. the performance of the drives during complete crane motion
1226 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 49, NO. 3, MAY/JUNE 2013
Fig. 17. Plot of total trolley drive current feedback relative to the sum of the
motor’s nameplate (continuous) ampere rating.
Fig. 14. Plot of hoist drive current feedback relative to the motor’s nameplate
(continuous) ampere rating.
Fig. 15. Histogram of the drive ampere feedback at 20-A intervals relative to Fig. 18. Histogram of the drive ampere feedback at 15-A intervals relative to
the motor’s continuous rating. the motor’s continuous rating.
ACKNOWLEDGMENT
The author would like to thank the assistance of the pa-
per mill’s woodyard production team leader, crew, and elec-
trical engineer for their permission to acquire site data and
B. Tremblay, the Senior Field Support Engineer of Rockwell
Automation, for supplying drive feedback parameters for anal-
ysis and modernization pictures used in this paper.
Fig. 22. One of the four gantry motion motors postretrofit.
R EFERENCES
[1] NEMA Standards Publication, Motors and Generators, MG1-1993 Rev 3,
VII. C ONCLUSION 1993, Part 12, p. 14.
[2] Crane Drives Manual—AC Cranes, General Electric, Fairfield, CT, USA,
From the data analyzed, the method used to size variable Nov. 23, 1959, Section 2A, p. 5.
frequency induction motors from existing WR motors with [3] A-70312 Torque Speed Curves for a GE 30 HP Crane Duty Motor
HR-444-B, 04-20-1933, General Electric, Fairfield, CT, USA.
limited data has merit. The histograms and charts indicate the [4] IEEE Standard for Petroleum and Chemical Industry-Premium-Efficiency,
ampere draw for the hoist, trolley, and gantry motors was less Severe-Duty, Totally Enclosed Fan-Cooled (TEFC) Squirrel Cage Induc-
than the motor continuous rating. There are large variances in tion Motors-Up to and Including 370 kW (500 hp), IEEE Std. 841-2009,
2009, p. 5, Section 4.5.
the loads that are hoisted and wind gusts that affect loading
of the trolley and gantry motions. The data collected may not
be indicative of all operating conditions during other environ-
mental conditions, and these are applicable only to this site Mike Kozlowski (SM’05) received B.S. degrees in mining and electrical
engineering from West Virginia University, Morgantown, WV, USA.
location. Other applications would have to be analyzed on a He is a Drive System Consulting Engineer with ABB Process Automation
case-by-case basis. Pulp and Paper, Greenville, SC, USA.