Baldor_LEMUG

General Purpose AC Motor Considerations
for Nuclear Power Plants (< 600 V)
EPRI LEMUG Meeting
Hilton Minneapolis
August 27 – 30, 2012
“To be the best as determined by our customers”

 Motors for the Nuclear Power Industry
 General Purpose Motors
 “Zero Tolerance” Motors
 Energy Independence & Security Act of 2007 (EISA)
 Company Background
 Q & A
Topics
| © Baldor Electric Company2

Motors for the Nuclear Power Industry
 General Purpose (GP) Motors:
› 3-Phase, Squirrel-cage AC Induction motors, random-wound, < 600 V
› NEMA Design B
› Standard ratings with standard operating characteristics
› Not restricted to a particular application or type of application
› Direct Coupled
› Energy efficient motors as mandated by the 2007 Energy Independence and
Security Act (EISA)
 Specialized (Purpose Built) Motors:
› Safety Related Non-Environmentally Qualified (EQ)
› Safety Related EQ
› Side Loaded (belt drive)
› Inverter Duty
› Frequent Start Motor
› High Inertia Load (long acceleration)
› High Torque (NEMA Design D)
› Hazardous Locations Motor, Class I & Class II, Division 1 or 2

 ODP (Open Drip Proof)
› Air passes freely through the motor
› Clean, dry, low-humidity environments – Indoor
› Rolled steel or cast iron frames, aluminum or cast iron end
brackets and conduit box (typical)
› Weather Protected Type I (WP-I) / IP-23 enclosures available in
larger frame sizes
› Typically available from stock
 TEFC (Totally Enclosed Fan Cooled)
› Cooling air circulated by an external shaft-driven fan
› Moderate dust, moisture, and corrosive environments
› Rolled steel or cast iron frames, aluminum or cast iron end
brackets and conduit box, cast iron or steel fan cover (typical)
› Typically available from stock
General Purpose Motors

 Severe Duty:
› Severe dust, moisture, corrosion, and abrasive
environments
› Cast iron construction (frames, end brackets, conduit box)
› TEFC or TENV Enclosures, IP54
› Corrosion-resistant hardware
› Internal & external protective treatments
› Wide variety of electrical and mechanical configurations
 IEEE 841:
› Enhanced Severe Duty features for extreme environments
› 200, 230, 460, 575, 2300 and 4000 volts - 60Hz
› 3600, 1800, 1200 and 900 RPM
› NEMA Design B
› TEFC or TENV Enclosures, IP55+
› Temperature Rise 80 C max at rated HP
General Purpose Motors

Typical Severe Duty Motor Construction

Typical IEEE 841 Terminal Box Construction
Neoprene Gasket
Threaded
Conduit
Inlet
Ground Lug
Lead Separator
Gasket

“Zero Tolerance” – Overview
 Product definition: A line of NEMA frame size, low-voltage
motors designed and manufactured to the highest standards
with features that meet or exceed most user requirements to
provide many years of reliable service.
 Development drivers:
› Applications Working Group (AWG):
• Low Voltage Motor Procurement Spec
› Duke Energy Non-QA1 Motor Spec:
• Class H – VPI, Max Core Length per Frame Size
• 841 Enclosure, O/S Metal Fan, Precision Balance
• Special testing & documentation
› Cooling Tower motors for TVA BFN:
• 200 HP, 1800 RPM, 447T Frame, TEFC-841XL
• Class F – VPI, Sealed Windings
• Special testing & documentation

“Zero Tolerance” – Electrical Features
 NEMA Design B
 3 – 200 HP
 1200, 1800, & 3600 RPM
 460 or 575 V,
 3-phase, 60 Hz
 Suitable for inverter-duty, 20:1 VT or 4:1 CT
 Select designs suitable for 75% reduced voltage starting
 Direct on line (DOL) starting
 50 C Ambient
 1.15 SF
 Continuous Duty
 NEMA Premium® Efficiency levels or better
 Class H insulation, Class B temperature rise
 VPI encapsulated windings, 100% solids Epoxy

“Zero Tolerance” – Mechanical Features
 NEMA 182T – 449T Frame
 Cast iron construction
 Horizontal, foot-mounted, F-1 assembly (standard)
 TEFC, Severe Duty Enclosure, IP56
 Oversized cast iron conduit box
 Oversized Metal Cooling Fan (subject to electrical design)
 Die-cast aluminum rotor construction
 Open bearing construction (PLS)
 Precision Balance
 Exxon Mobil Polyrex EM grease
 Same-size bearing on each end (250 Frame+)
 Max core length per frame size
 Sealed bracket to frame fits
 2-part Epoxy paint system
 IEEE 841-style features:
› Shaft TIR, foot co-planarity, Inpro/Seal bearing isolators

 Documentation and Testing:
› Standard data pack:
• Dimension Sheet, Performance Data & Curves @ 100% voltage,
Thermal Limit Curves, Renewal Parts List, Wiring Diagram,
Equivalent Circuit Data, Standard Instruction Manual
› Routine Test Report with no-load vibration data
› Certificate of Conformance available
 General:
› Catalog numbers assigned for 460 V ratings
› Stocking program currently under consideration
• Estimated lead-times are 12 weeks from order entry for non-
stock ratings.
› Manufactured at the Gainesville, GA plant (ISO9001:2008)
› 5-year limited warranty
“Zero Tolerance” – Other Features

General Purpose Motor Feature Comparison
Motor Type: Severe Duty IEEE 841 "Zero Tolerance"
Catalog Reference No. ECP2334T-4 ECP82334T-4 EZT2334T-4
Mechanical Features
Frame, Fan Cover, End Plate & Conduit Box material Cast Iron Cast Iron Cast Iron
External cooling fan Non-metallic Non-metallic Bronze O/S
Conduit box lid gasket & lead separator gasket Neoprene Neoprene Viton
Bearing Size (DE/ODE) 309/309 309/309 309/309
Bearing Type Ball Ball Ball
Bearing Construction Open-PLS Open-PLS Open-PLS
Grease Type Polyrex EM Polyrex EM Polyrex EM
Frame Grounding Provisions Available Standard Standard
Vibration Pads on Endplates Available Standard Standard
Nameplate Material Stn. Steel Stn. Steel Stn. Steel
Shaft Slinger V-Ring (Nitrile) Inpro/Seal Inpro/Seal
No-load Vibration @ rated voltage & Hz (peak) <0.15 in/sec <0.08 in/sec <0.05 in/sec
Foot flatness tolerance 0.015" 0.005" 0.005"
Shaft runout (T.I.R.) 0.002" max 0.001" max 0.001" max
Sound power level (Typical) 74 dBA 74 dBA 74 dBA
Paint System 2-part Epoxy 2-part Epoxy 2-part Epoxy
Rotor Balance Standard Ultra-Standard Precision
TEFC Premium Efficiency Motors - 20 HP, 1800 RPM, 460 V, 3-Phase, 60 Hz, NEMA 256T Frame

General Purpose Motor Feature Comparison
Severe Duty IEEE 841 "Zero Tolerance"
Electrical Features
Insulation Class Class F Class F Class H
Temperature Rise @ 1.0 SF Class B Class B Class B
Winding Treatment, 100% solids Dip & Bake Dip & Bake VPI Encap.
Service Factor 1.15 1.15 1.15
Inverter Spike Resistant Insulation System Yes Yes Yes
Testing and Quality Assurance
No-load Vibration test report shipped with motor Available Standard Standard
Corona inception testing (NEMA Part 31.4.4.2) Yes Yes Yes
Documented final motor test data shipped with motor Available Standard Standard
ASTM B117-90 96-hour salt spray test compliance Yes Yes Yes
Quality Assurance Program ISO 9001:2008 ISO 9001:2008 ISO 9001:2008
Country of origin USA USA USA
Engineering Documentation
Motor Dimension Sheet Available Available Standard
Performance Curves & Data @ 100% Voltage Available Available Standard
Thermal Limit Curve Available Available Standard
Equivalent Circuit Data Available Available Standard
Installation & Operating Manual Available Available Standard
Renewal Parts List Available Available Standard
TEFC Premium Efficiency Motors - 20 HP, 1800 RPM, 460 V, 3-Phase, 60 Hz, NEMA 256T Frame

Energy Independence & Security Act of 2007
(EISA)
 What is EISA?
› Congressionally-mandated energy efficiency standards for
general purpose, 3-phase, AC motors,1 – 500 HP manufactured
in the US.
› Expands the mandated energy efficiency standards from the
Energy Policy Act of 1992 (EPAct) to a wider range of industrial
motors.
 When did EISA become effective?
› EISA applies to motors manufactured after December 19, 2010
 What are the efficiency standards under EISA?
› Motors previously covered by EPAct now have to meet NEMA
Premium® efficiency levels (Subtype I)
› Certain general purpose motors (Subtype II) not previously
covered by EPAct now have to meet EPAct efficiency levels

EISA Efficiency Requirements
• U-frame motors
• Design C
• Close-coupled pump motors
• Footless
• Vertical solid shaft normal thrust
motors (P-base)
• 8-pole motors
• 3-ph motors of not more than 600
volts (other than 230 or 460 volts).
• Fire Pump motors 1-200 HP
• Single phase motors
• DC motors
• Two digit frames (48-56)
• Multi-speed motors
• Medium voltage motors
• TENV and TEAO motors
• Design D with high slip
• Adjustable speed with optimized
windings
• Customized OEM mounting
• Intermittent duty
• Integral with gearing or brake
where motor cannot be used
separately
• Submersible motors
• General Purpose
• 1-200 HP 2-4-6 pole
• 230 or 460 volt 60 Hz
• Horizontal base mount
• With or without C-face or D-flange
• Includes IEC Metric frame motors
from 90 frame - up (except 100
frame).
• NEMA design A or B or IEC design N
• General
Purpose
• NEMA
design B
or IEC
design N
• Not more
than 600
volts
Premium Efficiency Table 12-12
EISA (Subtype I)
Energy Efficiency Table 12-11
EPAct (Subtype II)
Exempt Energy Efficiency Table 12-11
EPAct
HP
Previously Covered by EPAct?
1 – 200 HP 201 – 500 HP
Yes NoNo

Industrial Motor Type Selection
Motor Type Eff. Req. Load Characteristics Typical Applications
NEMA Design B EISA Centrifugal loads Centrifugal Pumps & Compressors
Low starting torque/inertia Blowers & Fans
Good speed regulation Drilling Machines, Grinders & Lathes
Short overload duration at full speed
NEMA Design C EPAct High starting torque due to high inertia or back pressure Reciprocating Pumps & Compressors
Normal load torque at full speed Ball & Rod Mills
Not subject to severe overloads at full speed Crushers
Good speed regulation
NEMA Design D Exempt Intermittent loads Punch Presses
Either high or low starting torque requirements Cranes & Hoists
Frequent start, stop, and reverse cycles Press Breaks
Flywheels to carry peak power demands Shears
Poor speed regulation is desirable Oil Well Pumps
Multi-Speed/ Exempt Low or high starting torque requirements Blowers & Fans
Adjustable Speed Constant Torque, Variable Torque, or Constant HP Machine Tools
running characteristics. Mixing Machines
Broad Constant Torque speed range. Conveyors
Extruders

Rating: 5 HP, 1800 RPM, TEFC 20 HP, 1800 RPM, TEFC
EPAct EISA EPAct EISA
Catalog No. CP3665T-4 ECP3665T-4 CP2334T-4 ECP2334T-4
Volts/Hz/Phase 460/60/3 460/60/3 460/60/3 460/60/3
Frame Size 184T L184T 256T 256T
FL Speed 1745 RPM 1750 RPM 1760 RPM 1765 RPM
FL Current 6.5 amps 6.6 amps 25.4 amps 24.0 amps
Eff. (Nom.) 87.5% 89.5% 91.0% 93.0%
Eff. (Min) 85.5% 87.5% 90.2% 92.4%
Power Factor 82.2% 79.7% 80.6% 83.8%
kVA/HP Code H J G G
LR Current 44.0 amps 46.0 amps 145 amps 145 amps
LR/FL Current 677% 697% 571% 604%
Typical Electrical Performance (Design B)

Rating: 5 HP, 1800 RPM, TEFC 20 HP, 1800 RPM, TEFC
EPAct EISA EPAct EISA
Catalog No. CP3665T-4 ECP3665T-4 CP2334T-4 ECP2334T-4
Frame Size 184T L184T 256T 256T
Core Length 3.25” 4.25” 4.75” 7.00”
Wire Weight 7.9 Lbs. 8.9 Lbs. 26.3 Lbs. 30.3 Lbs.
Fan OD 7.50” 7.50” 7.50” 9.00”
No. Stator Slots 36 36 40 40
No. Rotor Bars 45 45 48 48
Alum. Volume 33.3 in3
36.5 in3
104.8 in3
106.2 in3
Est. Weight 91 Lbs. 121 Lbs. 315 Lbs. 345 Lbs.
∆ Lbs. +30 Lbs. +30 Lbs.
∆ % +33% +10%
Typical Physical Comparison (Design B)

 Replacement motors must now meet current EISA
minimum efficiency standards:
› Electrical/motor performance impact:
• May have a lower Power Factor
• Higher RPM may reduce driven equipment efficiency
• Possible differences in accelerating torque
• Higher starting currents (nuisance trips, contactor sizing)
› Mechanical/physical impact:
• Safety Related motors may require seismic re-qualification
• Potential retrofit issues with extended frame lengths
• Spare parts requirements may change (fans, etc.)
EISA Compliance Issues – Nuclear Motors
Contact your motor supplier up-front to understand what you’re getting!

About Baldor Electric Company
 Acquired Reliance Electric Company and Dodge from
Rockwell Automation in January 2007
 Acquired by ABB in January 2011
› Wholly owned subsidiary within ABB’s Discrete Automation
and Motion (DM) division
• BU Motor & Generators
 Approximately 7,250 employees
 50 district sales offices/warehouses across the U.S. and
Canada
 26 International sales offices located in Europe, Far East,
Latin America, and Australia
 Products sold in more than 70 countries
 26 manufacturing locations
 Motors sold under the Baldor-Reliance and Reliance Electric
brands (Navy/Nuclear only)

About ABB
 134,000 employees in about 100 countries
 $38 billion in revenue (2011)
 Organized into five global divisions:
• Power Products
• Power Systems
• Discrete Automation & Motion
• Low Voltage Products
• Process Automation
 Formed in 1988 merger of Swiss and Swedish
engineering companies
 Predecessors founded in 1883 and 1891
 Publicly owned company with head office in Switzerland

Questions?
Bob Perdue
Product Manager, Specialty Motors
Baldor Electric Company – A Member of the ABB Group
Tel. 865.248.8240
jrperdue@baldor.com

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