Commissioning Motors and Generators

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Commissioning Motors And Generators
Note: The source of the technical material in this volume is the Professional Engineering Development Program (PEDP) of Engineering Services. Warning: The material contained in this document was developed for Saudi Aramco and is intended for the exclusive use of Saudi Aramcos employees. Any material contained in this document which is not already in the public domain may not be copied, reproduced, sold, given, or disclosed to third parties, or otherwise used in whole, or in part, without the written permission of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Electrical File Reference: EEX30205
For additional information on this subject, contact W.A. Roussel on 874-6160
Electrical Commissioning Motors and Generators
Content
Page
INTRODUCTION................................................................................................................ 1 SAUDI ARAMCO REQUIREMENTS................................................................................. 2 Motor and Generator Standards and Specifications.................................................... 2 NEMA MG-1............................................................................................................ 3 Size Classification .......................................................................................... 3 Application Classification............................................................................... 4 Variability of Speed Classification .................................................................. 4 Electrical Types Classification........................................................................ 5 Enclosure and Method of Cooling Classification ............................................ 6 EVALUATING MOTORS AND GENERATORS UPON RECEIPT ................................... 8 Visual Inspection....................................................................................................... 8 Verification Against Specifications ............................................................................ 8 Motor and Generator Nameplates .................................................................. 9 EVALUATING MOTOR AND GENERATOR INSTALLATION AND TESTING............12 Visual Inspection......................................................................................................12 Suitability .....................................................................................................13 Physical Damage...........................................................................................13 Personnel Protective Devices ........................................................................14 Cleanliness....................................................................................................14 Area Classification ........................................................................................14 Mechanical Inspection ..............................................................................................14 Mounting Bolts.............................................................................................15 Motor Alignment ..........................................................................................15 Shaft Rotation...............................................................................................15 Lubrication ...................................................................................................16 Rotor to Stator Air Gap Alignment ...............................................................16 Electrical Inspection and Test ...................................................................................16 Winding Resistance.......................................................................................17 Insulation Resistance.....................................................................................17
Dc High-Pot .................................................................................................19 Miscellaneous Electrical Tests.......................................................................21 Energization Tests ........................................................................................21 WORK AID 1: REFERENCES FOR EVALUATING MOTORS AND GENERATORS UPON RECEIPT ...................................................24 Work Aid 1A: Motor and Generator Technical and Construction Requirements........24 Method of Bearing Lubrication .....................................................................27 Work Aid 1B: Motor and Generator Winding, Wiring, and Space Heater Requirements ....................................................................................33 Work Aid 1C: Motor Rating Requirements ..............................................................35 Work Aid 1D: Data Schedules..................................................................................36 WORK AID 2: REFERENCES FOR EVALUATING MOTOR AND GENERATOR INSTALLATION AND TESTING ...................................42 Work Aid 2A: Testing Requirements........................................................................42 Work Aid 2B: Information, Formulas, and Tables for Use in Evaluating the Results of Insulation Resistance (Megger) Tests ................................43 Work Aid 2C: Information, Formulas, and Tables for Use in Evaluating the Results of Dc High-Pot Tests ............................................................44 Work Aid 2D: Miscellaneous Tests/Checks ..............................................................46 Rotating Rectifier Diode Check.....................................................................46 Air Gap Check..............................................................................................47 Work Aid 2E: Acceptable Values for No Load Run Test Data .................................47 Phase Current ...............................................................................................47 Phase Voltage...............................................................................................47 Percent Voltage Unbalance ...........................................................................47 Vibration Levels ...........................................................................................48 Winding Temperature ...................................................................................48 Bearing Temperature ....................................................................................48 % Ns When Excited......................................................................................48 Exciter Field Current.....................................................................................49 Motor Field Current......................................................................................49 Power Factor ................................................................................................49
Reactive Power (kVAR) ...............................................................................49 Work Aid 2F: Acceptable Values for Load Run Test Data .......................................49 Inspection/Check of Motor Alignment ..........................................................49 Phase Current ...............................................................................................49 Phase Voltage...............................................................................................50 Percent Voltage Unbalance ...........................................................................50 Vibration Levels ...........................................................................................50 Winding Temperature ...................................................................................51 Bearing Temperature ....................................................................................51 Voltage Dip on Start (%) ..............................................................................51 Acceleration Time (Sec)................................................................................51 % Ns When Excited......................................................................................51 Exciter Field Current.....................................................................................51 Motor Field Current......................................................................................51 Power Factor ................................................................................................52 Reactive Power (kVAR) ...............................................................................52 Work Aid 2G: Saudi Aramco Pre-Commissioning Form ...........................................52 Work Aid 2H: Excerpts from GI 2.710.....................................................................71 GLOSSARY........................................................................................................................74
Table of Figures
Page
Figure 1: Ac Medium Machine Ratings (From NEMA MG-1-1987) ......................... 4 Figure 2: Typical Results of High-Pot Tests.............................................................20 Figure 4: Saudi Aramco Motor and Generator Material and Installation Requirements (from SAES-P-113) ..........................................................25 Figure 5: Motor Construction Technical Requirements ............................................26 Figure 6: Critical Speeds of Motors .........................................................................26 Figure 7: Bearing Types ..........................................................................................27 Figure 8: Bearing Lubricants ...................................................................................27 Figure 9: Sleeve Bearing Lubrication .......................................................................27 Figure 10: Motor and Generator Bearing Technical Requirements ...........................28 Figure 11: Mechanical Noise and Vibration Monitoring ...........................................28 Figure 12: Motor Enclosure Protection and Specification Requirements. .................29 Figure 13: Maximum Allowable Insulation Temperature ..........................................30 Figure 14: Motor Enclosure Cooling Requirements .................................................30 Figure 15: Nameplate Construction and Minimum Information Requirements ..........31 Figure 16: NEMA Frame Induction Motor Technical Requirements for Motors that are Rated Less Than 0.746 KW (from 17-SAMSS-503) ...................32 Figure 17: Motor and Generator Winding Construction Requirements .....................33 Figure 18: Wiring and Grounding Requirements ......................................................34 Figure 19: Space Heater Design and Construction Requirements .............................34 Figure 20: Space Heater Temperature Requirements for Classified Areas.................35 Figure 21: Motor Selection Table (from SAES-P-113) ............................................35 Figure 22: Ac Motor Locked-Rotor KVA per Horsepower (From NEMA MG-1) ...36 Figure 23: NEMA Frame Motor Data Schedule (from 17-SAMSS-503) ..................37 Figure 24: Induction Motor Data Schedule (from 17-SAMSS-502) .........................38 Figure 24: Induction Motor Data Schedule (from 17-SAMSS-502) (Cont'd)............39 Figure 25: Synchronous Motor Data Schedule (from 17-SAMSS-502) ....................40 Figure 25: Synchronous Motor Data Schedule (from 17-SAMSS-502) (Cont'd) ......41 Figure 26: Dielectric Absorption Ratio Chart...........................................................44
Figure 27: Typical Results of High-Pot Tests...........................................................46 Figure 28: Radial Air Gap Values ............................................................................47 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors........................53 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................54 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................55 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................56 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................57 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................58 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................59 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................60 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................61 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................62 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................63 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................64 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................65 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................66 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................67 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................68
Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................69 Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)......................70 Figure 30: GI 2.710 Excerpt....................................................................................72 Figure 30: GI 2.710 Excerpt (Cont'd) ......................................................................73
INTRODUCTION Once a motor or generator for a given installation is chosen, the motor or generator is ordered, shipped, and received. Once received, the motor is receipt inspected and tested as part of the commissioning process. The commissioning process for motors and generators in Saudi Aramco facilities ensures that a safe and cost-effective system is installed that performs to the specifications of the facility for the projected operating lifetime of the facility. Experience has shown that the time and effort that is expended up front to ensure safety, quality control, and adherence to Saudi Aramco and industry standards minimize subsequent equipment failure. The motor and generator commissioning process involves evaluations, verifications, and checks that determine whether the proper equipment specifications and installation requirements are met. Tests are performed, and the test results are evaluated to determine whether the motor or generator will operate properly and safely after it is installed. When a motor or generator is satisfactorily inspected and tested during the commissioning process, it should operate in accordance with manufacturer's specifications for its maximum useful life. Electrical Engineers must be able to direct commissioning of new motors and generators. This Module provides information on the following topics that are pertinent to the commissioning of motors and generators for Saudi Aramco installations: Saudi Aramco Requirements Evaluating Motors and Generators Upon Receipt Evaluating Motor and Generator Installation and Testing
SAUDI ARAMCO REQUIREMENTS Large process and process support equipment relies on motors for primary and ancillary functions throughout the manufacturing process (e.g., fans, circulation pumps, and blowers). Generators are used to supply power to motors and other equipment. Although motors and generators are usually at the opposite ends of the electrical distribution system (i.e., motors use the power that generators supply), they are similar in construction. Motors and generators have a shaft, a rotating element (rotor), a stationary element (stator), and an enclosure. The use of motors and generators in industrial settings requires that the motor or generator enclosure provide protection against industrial environmental hazards, such as dust or moisture. Because of the heat that is created by motors and generators, some type of cooling system must be also provided. From this brief overview, it should be clear that the design and construction requirements for motors and generators are similar. During the commissioning process, the Electrical Engineer will be required to be familiar with the design and construction requirements of motors and generators. This section of the module will describe the Saudi Aramco requirements for motors and generators. Motor and Generator Standards and Specifications Several Saudi Aramco standards and specifications contain minimum design and technical requirements for motors and generators that are installed in Saudi Aramco facilities. Each of these Saudi Aramco documents uses the National Electrical Manufacturers Association (NEMA) Standard MG-1 as a base reference. The following paragraphs contain a brief overview of the Saudi Aramco standards and specifications that are to be used during the commissioning process for motors and generators. The minimum mandatory requirements for the procurement and installation of induction and synchronous motors and generators that are installed in Saudi Aramco industrial facilities are defined in SAES-P-113, Motors and Generators. The minimum mandatory technical requirements for 460 V and below, 60 Hz, NEMA Frame induction motors that are rated from 0.746 to 185 KW (1 hp through 250 hp) that are installed in Saudi Aramco industrial facilities are defined in 17-SAMSS-503, NEMA Frame Motors. 17SAMSS-503 does not cover submersible motors, overhead crane motors, and valve-operator motors. The minimum mandatory technical requirements for form-wound squirrel-cage induction and brushless salient-pole synchronous motors that are installed in Saudi Aramco industrial facilities are defined in 17-SAMSS-502, Form Wound Induction and Synchronous Motors. 17-SAMSS502 covers form-wound squirrel-cage induction and brushless salient-pole synchronous motors that are rated 150 kW (200 hp) and above.
The minimum technical requirements for three-phase, 60 Hz, synchronous generators that are rated 125 kVA (100 kW) through 1250 kVA (1000 kW) that are installed in Saudi Aramco industrial facilities are defined in 17-SAMSS-510, Synchronous Generators. NEMA MG-1 MG-1 is a NEMA publication that contains motor and generator standards. The NEMA MG-1 publication is intended to assist users in the proper selection and application of motors and generators. The type of information that is contained in NEMA MG-1 pertains to the construction, the manufacture, the performance, the safety, and the testing of ac and dc motors and generators. A detailed discussion of the different types of motors and how they are designated by NEMA MG-1 is beyond the scope of this Module; however, a brief overview of the classifications of motors and generators will be provided. For a detailed discussion of motors and generators, refer to EEX 203, Motors and Generators. In accordance with MG-1, motors and generators can be classified by size, application, variability of speed, electrical type, and enclosure and method of cooling. Size Classification The machine size classifications are small, medium, and large. The sizing of small and medium machines can depend on frame measurement parameters as well as ratings. Medium dc machines are machines that have a continuous, open construction rating of up to and including 1.25 hp per rpm for motors or 1.0 kW per rpm for generators. Dc machines that have higher ratings are considered large machines. Medium ac machines are machines that have a continuous, open construction up to the values that are provided in Figure 1. Ac machines that have higher ratings are considered to be large machines. For commissioning Saudi Aramco motors or generators, the size requirements for the particular installation must be met and will vary from installation to installation.
Figure 1: Ac Medium Machine Ratings (From NEMA MG-1-1987)
Application Classification There are three main application classifications for motors in accordance with NEMA MG-1: general purpose (both dc and ac), industrial (both ac and dc), and definite and special purpose motors. The basic difference between general purpose and industrial motors is that the industrial motors generally have larger ratings and more stringent construction and performance characteristics. Definite and special purpose motors have application-specific rating, construction, and performance characteristics. During the commissioning process, the Electrical Engineer must ensure that the application classification of the motor that is being commissioned is correct for the installation. Variability of Speed Classification The classifications of motors according to variability of speed are dependent upon how the motor speed reacts to a varying load, and whether the speed of the motor can be controlled. For motor commissioning, the Electrical Engineer must ensure that the variability of speed classification of the motor must be the best fit for the motor application. The variability of speed classifications are as follows:
Constant-Speed Motor Varying-Speed Motor Adjustable-Speed Motor Adjustable Varying-Speed Motor Multi-Speed Motor Electrical Types Classification The classification of motors and generators by electrical type is one of the main ways in which motors and generators are specified or described for installations. For Saudi Aramco motor or generator commissioning, the Electrical Engineer must determine that the electrical type of the motor or generator matches the electrical type that is required for the installation. The Electrical Engineer makes the determination by comparing the electrical type of the motor or generator to the electrical type that is required by the electrical drawings or prints. In accordance with NEMA MG-1, the major electrical type classifications of motors and generators are as follows: Ac Motors Induction Synchronous Polyphase Single-Phase Universal
Ac Generators Induction Synchronous
Dc Motors Shunt-Wound Series-Wound Compound-Wound
Dc Generators Shunt-Wound Compound-Wound
Enclosure and Method of Cooling Classification The classification of motors and generators according to the enclosure and methods of cooling is another way to specify motors and generators for installations that is widely used in industry. NEMA MG-1 allows the use of numerous types of motor enclosures; however, only the following three types of NEMA MG-1 enclosures are approved for use in Saudi Aramco applications: Totally-enclosed fan-cooled (TEFC). Environmental protection totally-enclosed air-to-air cooled (CACA). Weather protect type II (WP-II). NEMA MG-1 defines a TEFC enclosure as a totally-enclosed fan-cooled machine that is equipped for exterior cooling through use of a fan or fans that are integral with the machine but that are external to the enclosing parts. TEFC enclosures without heat exchangers are not permitted for motors that are rated above 11,000 kW (15,000 hp). This requirement is due to the heat dissipation requirements of the motor. NEMA MG-1 defines a CACA as a totally-enclosed air-to-air cooled machine that is cooled through circulation of the internal air through a heat exchanger that, in turn, is cooled through circulation of external air. A CACA enclosure is provided with an air-to-air heat exchanger for cooling the internal air, a fan or fans that are integral with the rotor shaft or separate for circulating the internal air, and a separate fan for circulating the external air. CACA enclosures should be specified for induction motors and for salient pole synchronous motors that are rated up to 11,000 kW (15,000 hp). NEMA MG-1 defines a WP-II as an open machine with ventilating passages that are so constructed as to minimize the entrance of rain, snow, and air-borne particles to the electric parts, and with ventilated openings that are so constructed as to prevent the passage of a cylindrical rod that is 0.75 inch in diameter. The WP-II type of enclosure does not afford the same degree of protection as TEFC types, but it may be acceptable for synchronous motors with rated outputs that are above 11,000 kW (15,000 hp) where the cost advantage over a TEFC type of enclosure is significant.
In addition to environmental protection and methods of cooling, machine enclosures are also classified for installation in hazardous areas. There are many different types of hazardous areas; however, only the usual Class I, Division 1 and 2 locations with Group D hazards that are found in Saudi Aramco installations will be discussed. For a Division 1 area, the motor enclosure must be explosion proof (Exd). Because of the TEFC ruggedness and simplicity, the totally-enclosed flameproof motor is preferred for motor sizes up to about 500 kW (700 hp). For larger motor sizes, the normal practice is to avoid Division 1 locations because of the cost of the enclosures. For a Division 2 area, the motor enclosure must be non-sparking (Exn). The type of protection "n" is such that during normal operation, the motor is not capable of causing ignition, and a fault that is capable of causing ignition is not likely to occur; therefore, any type of enclosure that prevents sparks can be utilized.
EVALUATING MOTORS AND GENERATORS UPON RECEIPT The installation of motors and generators in Saudi Aramco facilities is a process that occurs over a period of time. The motors drive equipment (e.g., pumps) that forms the base of the manufacturing or refining process. The generators supply power to the equipment. Motor and generator installations begin with an identified need for motors or power generation equipment in a new facility. After the facility design is approved, the machines are ordered from the manufacturer. When the machines are received from the manufacturer, they must be evaluated to ensure that they are proper for the installation. The purpose of the evaluation is to verify that correct motors or generators were received from the manufacturer and that the proper installation specifications and parameters were met. This section will describe how motors and generators are evaluated upon receipt. Visual Inspection When motors or generators are received from the manufacturer, a visual inspection should be performed. The purpose of the visual inspection is to verify that the motors or generators that were received from the manufacturer are in good physical condition and that the enclosures and cooling equipment (if present) have not been damaged during shipment. During the initial visual inspection, the inspection personnel look for obvious equipment damage and determine whether all necessary equipment (e.g., connection boxes or conduit boxes) are present. A detailed inspection of the motor or generator is also performed when they are completely installed at the site or facility. Verification Against Specifications When a new facility or facility modification is at the equipment installation stage, the design of the installation has already been completed. The type and classification of a motor or a generator that is selected for a specific installation should be shown in the drawings, prints, or specifications for the installation. The purpose of verifying motors or generators against the specifications is to ensure that the machine that is being installed meets Saudi Aramco and industry standards.
Generally, the verification against specifications consists of a determination of whether the machine that is to be installed matches the machine that is specified for the installation. In most cases, this determination is accomplished by reading an electrical plan that identifies the motor or generator size, application, speed control, electrical type, enclosure type, and method of cooling. The Electrical Engineer inspects the manufacturer's nameplate data on the machine, and he compares them to the requirements on the electrical plan to determine whether the correct machine is being used. In other situations, the Electrical Engineer must rely on his knowledge of the correct application of motors and generators (e.g., types and enclosures) to determine whether the correct machine is being used. The data sheets that were used to order the machine from the manufacturer should also be consulted. Example data sheets are provided in Work Aid 1. Any quality control, quality assurance, and test data that are provided with the motor or generator by the manufacturer should also be reviewed. Motor and Generator Nameplates All motors and generators that are used in Saudi Aramco facilities should have a nameplate that is clearly visible on the machine. The nameplate should contain manufacturer-type information. The information that describes the machine manufacturer's information should consist of the manufacturer's name, the type designation, and the serial number. Because of the different types and classifications of motors and generators, nameplates may contain many different kinds of information. The nameplates of Saudi Aramco motors and generators should include all the information that is required by NEMA MG-1 and IEC 34-1 and the additional information that is required by SAES-P-113. The following is a list of the information that NEMA MG-1 requires on machine nameplates: Manufacturer information (e.g., name, serial number, and type designation). Horsepower output or kilowatt. KVA output (ac generators only). Power factor (ac machines only). Frequency (ac machines only). Voltage. Rated-load amperes. Rated field/armature voltage and current (if applicable). Time rating. Temperature rise (or maximum ambient temperature). RPM at full (or rated) load.
Number of phases (ac machines only). Code letter for locked rotor KVA (ac motors only). Winding (dc machines only). Insulation system designation. The words "Impedance or Thermally Protected" (if applicable). A brief discussion of nameplate items will be provided. Because Electrical Engineers should have a working knowledge of the electrical engineering principles that are associated with motors and generators, fundamental ratings, such as voltage, current, and frequency, will not be covered. The time rating and temperature rise are nameplate values that describe the ability of machine insulation and cooling medium to prevent the machine from overheating at full load conditions for extended periods of time. The time rating (usually given in minutes) is the time that it takes for the machine to exceed maximum temperature values under full load and overload conditions. The temperature rise is a maximum temperature value above the ambient temperature of the machine. The temperature rise corresponds to an insulation system class designation with the machine operating at the machine rating at the base speed. For machine applications that require an overload capability, a service factor of > 1.0 is used. The service factor is a multiplier that takes into account overload conditions. The nameplate of most ac motors must be marked with a locked-rotor kVA "code." The code is a letter designator that corresponds to a locked-rotor kVA value per horsepower. A locked-rotor kVA value per horsepower table is provided in Work Aid 1. Motor and generator insulation classes are divided into four classes that correspond to the thermal endurance of the machine for temperature rating purposes. The four insulation system class designators are A, B, F, and H. The minimum requirements for insulation classes are provided in Work Aid 1. When a small motor is equipped with a thermal protector, the words "thermally protected" are provided on the nameplate. The words "impedance protected" are provided on the nameplate of small motors that are manufactured with sufficient impedance to withstand the overheating that occurs when a motor is overloaded or fails to start.
10
The following additional data are required by SAES-P-113 and can be supplied on a separate nameplate(s): Buyer's purchase order number. Year of manufacture. Manufacturer's location. Manufacturer's order reference number. Anti-friction bearing number and manufacturer. Class, group, and division (explosion-proof motors only). Rotor weight. Total weight of motor. Saudi Aramco also requires that a separate nameplate be supplied to show the direction of motor rotation. The direction of rotation should be indicated by an arrow, and the nameplate should be located on the non-drive end of the motor. Nameplate(s) and rotation arrows must be made from 300 series stainless steel or monel, must be securely fastened to the motor by pins of similar material, and must be located for easy visibility. The entries on the nameplates must be marked by etching, engraving, or other permanent method of marking. To verify that a motor that is installed in a hazardous area is permitted in that area, additional information must be included on the nameplate. All the information that is required by NEMA MG-1 must be on the nameplate, plus the following additional information: Class, division, and/or group of hazardous atmosphere type for which the machine is approved. Type of protection that is provided. Temperature class for which the motor is approved. Maximum exposed temperature of the machine.
11
EVALUATING MOTOR AND GENERATOR INSTALLATION AND TESTING The process of determining whether machines should be commissioned is to verify that all of the electrical inspections and tests have been properly performed and to verify that the test results meet the specifications that are designated by the applicable Saudi Aramco and industry standards. Installation inspections are performed to verify that proper machine installation materials are used, that installation specifications and parameters are met, and that proper installation procedures are followed. The installation inspection is conducted to ensure that machines will function properly once they are installed. Electrical tests are performed to check the ability of machines to function under all operating conditions and loads. Installation tests should detect shipping or installation damage, gross manufacturing defects, or errors in workmanship or installation. The Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors, contains guidance on the items that should be inspected, checked, and tested during the commissioning of rotating machine installations. Form P-019 is provided in Work Aid 2. The proper evaluation of inspection and testing data during the commissioning process can maximize the operating time of equipment installations through a determination of trends towards failure. Failure prediction can drastically reduce equipment down-time; if a failure is predicted, operational changes can be made, maintenance can be performed, or equipment that is failing can be replaced in a controlled manner. If a problem is corrected before it causes damage, operating costs will be lower because a malfunction can cause associated (or nearby) equipment damage and disruption of service, or the problem can activate emergency repair crews. A failure in any one of the many inspections, checks, or tests that are performed on rotating machines during the installation and testing evaluation is sufficient to prevent the machine from being commissioned. Visual Inspection Visual inspections are used to assess the physical condition of machines during the commissioning process. A visual inspection is a pass/fail verification about a particular aspect of the physical condition or the operation of equipment. Because the criteria that are established to determine the acceptability of the visual inspections can be subjective, the visual inspections should be performed by an experienced Electrical Engineer. Visual inspection items for motors are listed in Saudi Aramco Pre-Commissioning Form P-019, NEMA Frame, Form Wound Induction and Synchronous Motors. Because of the manufacturing and performance similarities between motors and generators, many of the inspection items are the same for generators as they are for motors.
12
Because of the large number of inspection items that are associated with rotating machines, there are several courses of action for visual inspection failure. The course of action depends on the part of the machine that failed the visual inspection. For example, a failure of cleanliness visual inspection can generally be corrected through cleaning the machine. A physical damage or suitability inspection failure will probably require the replacement of the damaged machine component. The following visual inspections are used to assess the condition of rotating machines in Saudi Aramco systems: Suitability Physical Damage Personnel Protective Devices Cleanliness Area Classification Suitability The purpose of the suitability visual inspection is to determine whether the motor is appropriate for the application. Under normal circumstances, the suitability of the machine should be determined before it is placed into the system; however, a visual inspection should be performed to ensure that the motor is of the correct size and type for the installation, and that the motor classification is consistent with the area classification of the installation site. To determine the suitability of a motor, a visual inspection of the nameplate data should be performed and compared to the electrical system single line diagram. Physical Damage Physical damage to a motor can lead to motor failure during critical system operations. Because motors support fluid flow (e.g., lubricating or cooling oil), a motor failure can lead to catastrophic equipment failure, fire, personal injury, or death. Any physical damage to a motor or missing parts that were noted during the physical damage visual inspection requires the immediate replacement of the damaged or missing component. The most obvious and common forms of physical damage are cracks, dents, missing or broken pieces, and bent ventilation openings. The purpose of the physical damage inspection is to identify whether corrective maintenance or component replacement is necessary. Motors that show any form of physical damage, no matter how small, should be determined to have failed the physical damage inspection.
13
Personnel Protective Devices Because of both its mass and its speed, rotating equipment is dangerous to personnel who work around it. The electric power that is required to operate rotating equipment also makes it dangerous. To prevent injury to personnel, all rotating equipment is required to be installed with personnel protective devices. Such devices consist of screens, guards, and other items that protect operations and maintenance personnel from contacting rotating surfaces and hazardous voltage potentials. The purpose of the personnel protective devices inspection is to ensure that the devices are properly installed prior to commissioning. Cleanliness The purpose of the cleanliness visual inspection is to ensure the proper operation of the machine over the maximum operating life of the machine. The accumulation of dirt over a period of time will impede the proper operation of the machine (e.g., rotor and brushes) and will reduce the dielectric strength of the insulation. Dust and dirt will also create additional ground paths that reduce the efficiency of the motor and cause overheating and long-term damage. The accumulation of heavy amounts of dust and dirt should be cleaned away from the machine during maintenance cycles. Motors that are installed in extremely dirty, dusty, or humid areas may have to be cleaned more often than once during each maintenance cycle. Area Classification Because industrial settings contain various hazardous areas, it is important that the machine that is installed has the correct enclosure and cooling for the area classification. The purpose of the area classification visual inspection is to verify that a motor that is installed in a hazardous area is permitted in that area. During the commissioning process, the Electrical Engineer should verify that the enclosure classification information that is included on the machine nameplate (e.g., Exd) matches the equipment prints, drawings, and the actual motor installation conditions. Mechanical Inspection A mechanical inspection is used to assess the ability of the machine to physically perform the mechanical movements that are necessary for proper operation. Mechanical inspection items are listed in Saudi Aramco Pre-Commissioning Form P-019, NEMA Frame, Form Wound Induction and Synchronous Motors, which is provided in Work Aid 2. Because there are several mechanical inspection items that are associated with motors, there are a number of corrective actions for a mechanical inspection failure. The corrective action depends on the part of the machine that failed the inspection. For example, a mounting bolt inspection failure can usually be corrected through adjustment of the bolts with a torque wrench.
14
The general mechanical inspections and tests that are performed on motors that are installed in Saudi Aramco systems are as follows: Mounting Bolts Motor Alignment Shaft Rotation Lubrication Rotor to Stator Air Gap Alignment Mounting Bolts The purpose of a mounting bolt inspection is to verify that the motor's mounting bolts are securely fastened. The bolts and frame mounts must be capable of preventing the motor from coming loose during mechanical failure or electrical fault conditions. To perform the mounting bolt check, the manufacturer's technical manual is consulted for the proper bolt torque value. A torque wrench is then used to determine the amount of torque at the bolt. Improper torque values are immediately corrected. Motor Alignment Motors are installed in facilities to perform a function. As the motor shaft turns, the mechanical work is transferred to another piece of equipment (e.g., pump or compressor). The purpose of the motor alignment mechanical inspection is to ensure that the shaft of the motor is correctly aligned and coupled to the driven equipment. Shaft Rotation The shaft rotation is generally performed in conjunction with the motor alignment visual inspection. The purpose of the shaft rotation mechanical inspection is to ensure that the shaft of the motor rotates freely and that there are no visual or audible indications of scraping or binding as the shaft turns. For ac induction motors that do not have slip rings or a commutator, the shaft rotation mechanical inspection is performed by rotating the shaft by hand and inspecting the shaft as it rotates. For dc machines and ac machines with slip rings, the Electrical Engineer should also inspect the brushes and brush holders during the shaft rotation mechanical inspection.
15
Lubrication The lubrication system visual inspection should be performed in conjunction with the cleanliness visual inspection. The purpose of the lubrication visual inspection is to ensure that the motor bearings will be provided with proper lubrication upon energization of the motor. The items that are inspected in the performance of the lubrication system visual inspection are dependent on the type of lubrication system with which the motor is equipped. Motors can be equipped with the either self-contained or external lubrication systems. Most motors are equipped with self-contained lubrication systems. These systems use grease or oil to provide the required lubrication to the motor bearings. The lubrication system visual inspection that is performed on a self-contained lubrication system should consist of a visual inspection of the bearing cavity or the oil reservoir (as applicable). Initial data records should be inspected to determine that the correct lubricating medium was used. Large motors are usually equipped with external lubrication systems. These systems use an oil pump and associated oil pipes to provide the motor bearings with a continuous supply of lubrication. External lubrication systems usually contain a pump, an oil sump, an oil filter, monitoring equipment, and the associated oil system pipes. The external lubrication system visual inspection should consist of a visual inspection of the bearing cavity or the oil reservoir (as applicable), the oil sump level, the oil system piping, and the components. An oil sample from the oil sump should be drawn and analyzed. Initial data records should be inspected to determine that the correct lubricating medium was used. Rotor to Stator Air Gap Alignment The air gap between the rotor and the stator is checked. This air gap must be uniform to prevent mechanical noise, vibration, and misalignment. Electrical Inspection and Test During the commissioning process, electrical inspections and tests are performed to check the ability of motors to operate for a reasonable future period of time under all operating conditions and loads. Acceptance or installation tests will usually detect shipping or installation damage and gross defects or errors in workmanship in equipment construction. Once the installation and inspection data have been recorded and assembled, a methodical and consistent program of periodic data collection and evaluation should be established. As each new maintenance item, test, system addition, or system reconfiguration occurs, new inspections and data records will be required and should be added to the existing data on file.
16
Because an electrical inspection or test failure can be caused by a design flaw, a construction error, equipment age, or operational misuse, some kind of troubleshooting or maintenance activity should be performed on the faulty equipment. For example, an insulation resistance (megger) test failure can usually be rectified by cleaning the interior of the machine to remove dirt and carbon dust build-up. Some electrical inspection or test failures are not repairable, and they will require the replacement of the equipment before the motor can be commissioned. For example, a winding resistance test failure usually indicates a damaged or an improperly wound motor winding. The following electrical inspections, checks, and tests are performed on motors: Winding Resistance Insulation Resistance Dc High-Pot Miscellaneous Electrical Tests Energization Tests Winding Resistance The purpose of the motor winding resistance test is to verify that the winding resistance of all motor windings (e.g., rotor, stator, and exciter) are in accordance with the manufacturer's listed values. The motor winding resistance test may also identify loose connections or improper terminations within the motor enclosure. To conduct the motor winding resistance test, the winding under test is electrically disconnected from the motor. Once the winding under test is electrically removed from the system, the leads of a digital, low-resistance ohmmeter are placed across each isolated winding and measurements are taken. A digital, low-resistance ohmmeter can deliver enough power to the contacts to make accurate readings that have more validity than those readings that can be obtained through the use of an ordinary multimeter. The motor winding resistance is recorded on a test data sheet or on the Saudi Aramco Pre-Commissioning form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors. Technical data to evaluate the results of the motor winding resistance test can be found in the motor manufacturer's technical manual. Insulation Resistance The purpose of the insulation resistance (megger) test is to directly measure the insulation resistance of the motor components. The megger produces a high potential that is applied from the motor windings and other insulated parts to ground. The leakage current that is detected results in a megger meter readout of insulation resistance in megohms.
17
To conduct the insulation resistance megger test, each winding of a motor is electrically disconnected from the others if possible. Once the windings are disconnected, the megger is connected between each motor winding and ground, and the megger is operated. Insulation resistance megger tests must be conducted for each winding of the machine. Some larger synchronous motors contain digital equipment in the field winding circuits. Because the voltage potentials that are generated during the megger test can damage any connected electronic equipment, megger tests must not be performed on electronic equipment. A bearing insulation resistance test is also performed on motors that have insulated bearings. The insulation resistance values are recorded on a test data sheet or on Saudi Aramco Pre-Commissioning form P-019, NEMA Frame, Form Wound Induction and Synchronous Motors, in the recorded test data section. For Saudi Aramco motor installations, megger readings must be corrected to 50oC. Temperature correction of megger readings is performed by multiplying the megger value by an insulation resistance temperature coefficient (Kt). A table of various values of Kt is provided in Work Aid 2. During the commissioning process, the Electrical Engineer should evaluate the insulation resistance (megger) test values to ensure that the insulation resistance values that were recorded are greater than the manufacturer's minimum values. Minimum values of insulation resistance readings are provided in Work Aid 2. Any value of insulation resistance that is less than the minimum specification should be investigated by the Electrical Engineer who performs the test data evaluation. The ratio of two time-resistance readings (such as a 60-second reading that is divided by a 30second reading) is called a dielectric absorption ratio. The dielectric absorption ratio is useful in recording information about the insulation. If the ratio is a ten-minute reading that is divided by a one-minute reading, the value is called the polarization index. Because constant cranking is required for hand-cranked megger instruments, it is easier to run the test for only 60 seconds and take the first reading at 30 seconds. When a power-operated megger instrument is used, the results of running the test for a full ten minutes and taking readings at one minute and at ten minutes will give the polarization index. An explanation of the evaluation of the dielectric absorption ratio is provided in Work Aid 2.
18
Dc High-Pot The dc high potential (high-pot) test is performed to provide positive proof that a motor's insulation has sufficient voltage strength to ride out overvoltage surges. The dc high-pot test should be done prior to the initial energization of the motor and after satisfactory megohmmeter testing. The dc high-pot testing technique for motors involves the measurement of increased dc voltage that is applied to the motor under test. The value of the leakage current is tracked as the test voltage is increased through several steps, and this value becomes a criterion of the condition of the motor insulation. The Electrical Engineer should evaluate the dc high-pot test leakage current test data to ensure that the motor high-pot test data meet the minimum requirements of a successful test. To conduct the dc high-pot test, a test set is connected between the motor phase leads and ground. After the test set is connected, the initial test voltage, which is equal to 33% of the maximum test voltage, is applied to the motor. The maximum dc test voltage for a motor is calculated through use of the following formula: Maximum Voltage = 75% (1.7(2 x Rated Voltage + 1 kV)). The initial test voltage is held for ten minutes, and the leakage current, as read on the test set, is monitored. The value of leakage current is recorded at the end of each one minute interval. The polarization index is calculated from this test data through division of the leakage current after one minute by the leakage current that is obtained after ten minutes. When the first ten minutes of the test is complete, the test voltage should be raised from the initial value of 33% to the maximum value in ten equal steps. After each step increase in voltage, the voltage should be held at the new level for a period of one minute, and the leakage current should be recorded at the end of each minute. The results of a high-pot test are not compared to a specific value to determine whether the results are acceptable. Instead, the results of a high-pot test are analyzed for trends that indicate whether the insulation has sufficient strength to ride out overvoltage surges. A polarization index value of less than two or dc high-pot test data curves that indicate a steady increase in leakage current over the duration of the test should be investigated by the Electrical Engineer who performs the test data evaluation. Figure 2 shows a graphic display of the typical results of high-pot tests for both good and bad insulation. The graph that is shown in Figure 2A is for the first ten minutes of a high-pot test. The curve that represents good insulation shows, over the first one-minute interval, a steep rise in leakage current that is followed by a steady decrease in the value of leakage current over the remainder of the ten-minute interval. The curve that represents bad insulation shows a steady increase in the value of leakage current throughout the ten-minute interval. Such a curve indicates unsatisfactory insulation, and the high-pot test should be stopped.
19
The graph that is shown in Figure 2B is for the last ten minutes of the high-pot test. The curve that represents good insulation shows a slow, steady increase in the value of leakage current as the test voltage is raised from 33% to 100%. The curve that represents bad insulation shows a sharp upturn or knee when the test voltage is increased to the point at which the insulation starts to break down. A knee in the leakage current curve indicates unsatisfactory insulation, and the high-pot test should be stopped.
Figure 2: Typical Results of High-Pot Tests
20
Miscellaneous Electrical Tests In addition to the more familiar electrical tests, such as insulation resistance, Electrical Engineers who are commissioning motors should be familiar with miscellaneous motor tests. Two of the miscellaneous electrical tests that are conducted on motors are the air gap test and the phase rotation test. Air Gap - The radial air gap should be checked on motors that are rated at 5000 hp or above to ensure that the air gap is uniform and that it is within the manufacturer's specifications. An unequal air gap can cause unequal currents in the stator windings that will result in unequal heating of the stator windings. The unequal currents in the stator windings also can result in an unbalanced magnetic pull between the stator and the rotor, and an unbalanced magnetic pull increases the possibility of contact between the stator and the rotor while the motor is in operation. Such contact can result in catastrophic damage to the motor. The radial air gap should be checked at eight different points around the circumference of the stator. The radial air gap is checked through insertion of a feeler gauge between the rotor and the stator windings of a motor. The feeler gauge size that just bridges the gap between the rotor winding and the stator winding is the size of the radial air gap. Minimum acceptable values for radial air gap are provided in Work Aid 2. Phase Rotation Test - Phase rotation tests are performed to ensure that the motor will rotate in the correct direction and that the motor leads are properly marked to coincide with the power system leads. If the motor rotates in the wrong direction, damage can occur to the connected load. The phase rotation test is the final pre-energization requirement because this test actually is performed through energization of the motor. The phase rotation test consists of a visual verification that the motor leads are properly marked to coincide with the power system leads and that the motor shaft rotates in the correct direction. The phase rotation test is performed through a momentary application of power to the motor while the load is disconnected and through observation of the direction of shaft rotation. If the shaft rotates in the wrong direction, the connection between two of the motor leads and two of the power system leads must be switched. After the leads are switched, the phase rotation test should be repeated to verify that the direction of shaft rotation has been corrected. After the verification is complete, the motor lead markers also should be switched.
21
Energization Tests Energization tests are performed on a motor during the commissioning process to verify that the motor installation is free from defects, to verify that the motor operates within its design limits, and to establish baseline motor operational data. Before energization tests are performed on a motor, all of the discrepancies that were identified during the pre-energization portion of the commissioning process must be corrected. The two types of energization tests that are performed on motors during the commissioning process are the no load run test and the load run test. No Load Run Test - For an electric motor, a no load run test consists of the measurement of various operational parameters of the motor while the motor is in operation but before the motor is connected to the load that it was installed to drive. The no load run test is performed prior to connection of the motor to its load to ensure that the information that is obtained from the test only applies to the motor. If the information that is obtained from the test is unsatisfactory, and if the test is conducted with the motor connected to the load, the cause of the unsatisfactory condition would be more difficult to determine. Also, if a problem does exist with the motor, performance of the test with the motor connected to the load would be more likely to aggravate the problem. Before a no load run test is performed on a motor that is equipped with space heaters, the space heaters must be turned on and the space heater current must be measured. The space heater current is measured to verify that the space heaters properly operate (e.g., that there are no burned-out units or loose connections). To ensure that condensation does not form inside of the motor when the motor cools off after the test, the space heaters must be operational before the no load run test is performed. The operational parameters that are measured during a no load run test vary with the type of motor to be tested. No load run test evaluation information is provided in Work Aid 2. For induction and synchronous motors, the following operational parameters should be monitored during a no load run test: Phase current balance Voltage balance Vibration level RTD readings for bearings and stator windings For synchronous motors, the following additional operational parameters should be monitored during a no load run test: Field current Power factor and kVAR control
22
Load Run Test - For an electric motor, a load run test consists of the measurement of various operational parameters of the motor while the motor is in operation and while it is connected to the load that it was installed to drive. The load run test should be conducted after all of the necessary repairs/adjustments that were identified during the no load run test have been completed. The operational parameters that are measured during a load run test vary with the type of motor to be tested. Load run test evaluation information is provided in Work Aid 2. For induction and synchronous motors, the following operational parameters should be monitored during a load run test: Motor alignment Phase current balance Voltage balance Vibration level RTD readings for bearings and stator windings Voltage dip on start Acceleration time Test duration The following additional operational parameters should be monitored during a load run test for a synchronous motor: Field current Power factor and kVAR control
23
WORK AID 1:
REFERENCES FOR EVALUATING MOTORS AND GENERATORS UPON RECEIPT
The minimum mandatory requirements for the procurement and installation of induction and synchronous motors and generators that are installed in Saudi Aramco industrial facilities are defined in SAES-P-113. The minimum mandatory technical requirements for 460 V and below, 60 Hz, NEMA Frame induction motors that are rated from 0.746 to 185 KW (1 hp through 250 hp) that are installed in Saudi Aramco industrial facilities are defined in 17-SAMSS-503. 17-SAMSS-503 does not cover submersible motors, overhead crane motors, and valve-operator motors. The minimum mandatory technical requirements for form-wound squirrel-cage induction and brushless salient-pole synchronous motors that are installed in Saudi Aramco industrial facilities are defined in 17-SAMSS-502. 17-SAMSS-502 covers form-wound squirrel-cage induction and brushless salient-pole synchronous motors that are rated 150 kW (200 hp) and larger, at operating voltages of 2300 volts and above, three-phase, at both 50 and 60-hertz. Unless stated otherwise, the information in this Work Aid contains combined excerpts from accepted industry practices and from the following resources: SAES-P-113, Motors and Generators 17-SAMSS-503, NEMA Frame Motors 17-SAMSS-502, Form Wound Induction and Synchronous Motors 17-SAMSS-510, Synchronous Generators GI-2.710 NEMA MG-1 Work Aid 1A: Motor and Generator Technical and Construction Requirements
Figure 4 shows Saudi Aramco motor and generator material and installation requirements (excerpted from SAES-P-113).
24
General Installation Requirements
Fractional Kilowatt (Horsepower) Motors
High Voltage Application Installation Requirements
Motors for non-industrial facilities must meet the requirements of NEMA MG 1. Motors and generators must be installed in accordance with ANSI/NFPA 70 (NEC). Cable, conduit and/or other connections must not electrically bridge insulated bearings. Auxiliary instrumentation must comply with SAES-J-604. Generators that are rated 125 kVA (100 kW) through 1250 kVA (1000 kW) must comply with 17-SAMSS-510. Generators that are rated 2500 kVA and above must have surge protection rated in accordance with 17-SAMSS-502. Motors that are rated 0.746 kW (1 hp) and above must comply with 17-SAMSS-502 or 17-SAMSS-503. Motors for belt-driven fin-fans must be designed for vertical operation. Motors that are rated less than 0.746 kW (1 hp) must comply with NEMA MG 1. Motors that are rated less than 0.746 kW (1 hp) must comply with the following additional requirements: a) Motors for outdoor installation must be of the totally enclosed type. b) Motors for indoor installation must be of the drip-proof guarded type. c) The insulation system must be Class B minimum. d) Enclosures and terminal housings must be metallic. e) Single Phase Motors must be provided with a built-in thermal protective device. f) Fans must be metallic or reinforced fiberglass, and must be designed for dual rotation. Motors that are rated for operating speeds of 3600 RPM must not exceed 3000 kW (4000 hp) without written approval of the Saudi Aramco Chief Engineer, Dhahran. Surge tests of all 13.2 kV motors are required (refer to 17-SAMSS-502). Motors that are rated 4000 kW (5360 hp) must have pedestal bearings. Figure 4: Saudi Aramco Motor and Generator Material and Installation Requirements (from SAES-P-113)
25
Figure 5 shows motor construction requirements for Saudi Aramco installations. Stator The stator frame should be of fabricated steel construction, with sufficient strength and rigidity to withstand the stresses to which the stator may be subjected in handling, transport, or due to short-circuit or other forces when in service. Induction motors should have a cylindrical rotor of the squirrel-cage type. Synchronous motors are available in cylindrical rotors or salient pole rotors. Cylindrical synchronous motors are used in speeds in excess of 1800 rpm. Salient pole rotors come in two types: The laminated salient pole rotor with a cage damper winding in each pole face for starting. The solid pole rotor with solid bolted pole shoes. The solid pole rotor is the preferred type of synchronous salient pole rotor for Saudi Aramco installations. Figure 5: Motor Construction Technical Requirements
Rotor
The critical speeds of motors depend on the type of shaft that is used for the motor construction. Critical speeds of motors that are used in Saudi Aramco installations are shown in Figure 6. First Lateral Critical Speed 115% rated motor rpm 65 to 85% rated motor speed Second Lateral Critical Speed Not within 10% of 2 times rated motor rpm Not within 10% of 2 times rated motor rpm
Rigid Shaft Flexible Shaft
Figure 6: Critical Speeds of Motors
26
Bearing types are shown in Figure 7. Motor Size < 15 hp (11 kW) 15 hp (11 kW) > 200 hp (150 kW) * * Horizontal Motors Bearing Type 200 or 300 series ball bearings 300 series ball bearings Sleeve bearings Figure 7: Bearing Types
Bearing lubricants are shown in Figure 8. Bearing Type Anti-friction Sleeve Lubrication Oil or Grease Oil
Figure 8: Bearing Lubricants
Method of Bearing Lubrication Sleeve bearing lubrication methods are shown in Figure 9. Shaft Journal Velocity m/S Below 11 11 and above Type of Lubricant Uncooled ring or disc oil lubrication Circulated feed oil lubrication
Figure 9: Sleeve Bearing Lubrication
27
Figure 10 shows motor and generator bearing technical requirements. General Bearing Construction Ball bearings should be of the re-greasable shielded type, furnished without grease fittings, but equipped with plugs in the tapped holes that are normally provided for such fittings. Relief holes or drain plugs that are located 180o from the grease point should be provided. Pre-lubricated sealed anti-friction bearings are not acceptable. Horizontal motors that are rated <3730 kW (5000 hp) must have the bearings housed in the endbells of the motor. Horizontal motors that are rated 3730 kW (5000 hp) and larger must be provided with pedestal bearings that are supported by the motor baseplate. The bearing housing for horizontal motors with oil-lubricated bearings must be equipped with labyrinth type end seals and deflectors where the shaft passes through the housing. Vertical motors with oil or grease-lubricated bearings must be provided with a positive shaft seal on top and bottom bearings. Horizontal motors that are rated 375 kW (500 hp) and larger should have bearings that are electrically insulated from the motor frame or baseplate. A removable test link should be provided for the drive end bearing. Vertical motors that are rated 375 kW (500 hp) and larger should have an electrically insulated top bearing. Figure 10: Motor and Generator Bearing Technical Requirements Figure 11 shows motor and generator mechanical noise and vibration monitoring requirements. Mechanical Noise Vibration Monitoring The mechanical noise sound pressure level at one meter should not exceed 90 dB. Vibration monitoring equipment should not be used for motors below 185 kW (250 hp). For horizontal motors that are rated between 750 kW (10000 hp) and 3000 kW (4000 hp), one seismic detector must be mounted horizontally at each bearing. For horizontal motors that are rated 3001 kW (4001 hp) and above, two proximity detectors must be mounted 90o apart at each bearing. For vertical motors, seismic type vibration detectors must be mounted 90o apart around the circumference of the top bearing housing. Figure 11: Mechanical Noise and Vibration Monitoring
Saudi Aramco DeskTop Standards 28
Bearing Housing Protection
Bearing Insulation
Figure 12 shows motor enclosure protection and specification requirements. Motor main and auxiliary equipment boxes should meet or exceed the main motor enclosure requirements. Protection TEFC All Saudi Aramco motor enclosures must be protected to a level that is equal to the IEC level designation IP44. Totally Enclosed Fan-Cooled (TEFC) enclosures are allowed on motors that are rated less than 11,000 kW (15,000 hp). Permitted in zone 1, zone 2, and unclassified locations. Totally Enclosed Air to Air-Cooled (CACA) enclosures are required for use on all induction motors and for salient pole synchronous motors that are rated up to 11,000 kW (15,000 hp) when the motor's temperature rise exceeds the allowable temperature rise for class B insulation. CACA enclosures are required for use on induction motors that are rated greater than 11,000 kW (15,000 hp). CACA enclosures are required for use on synchronous motors where the cleaning cost over the life of the machine plus the capital cost of an open motor would be more than the cost of the CACA enclosure. CACA enclosures are permitted in zone 1, zone 2, and unclassified areas. Weather Protected (WPII) enclosures must be specified for synchronous motors that are rated above 11,000 kW (15,000 hp) where the lifetime motor cleaning costs plus motor capital costs are less than the capital cost of a CACA motor. WPII enclosures are permitted in zone 2 and unclassified locations. Motors up to 150 kW (200 hp) require a grounding stud. Motors at or above 150 kW (200 hp) require a grounding pad Figure 12: Motor Enclosure Protection and Specification Requirements.
CACA
WPII
Grounding Requirements
For motors that are installed in classified environments, special enclosure requirements are necessary. Class I, Division 1 and 2 locations with Group D hazards are the common classified environments that are found in Saudi Aramco installations. For a Division 1 area, the motor enclosure must be explosion-proof (Exd). The totally enclosed flameproof motor is preferred for motor sizes up to about 500 kW (700 hp) because of the TEFC ruggedness and simplicity. For larger motor sizes, the normal practice is to avoid Division 1 locations because of the cost of the enclosures.
29
For a Division 2 area, the motor enclosure must be non-sparking (Exn). The type of protection "n" is such that during normal operation, the motor is not capable of causing ignition, and a fault that is capable of causing ignition is not likely to occur; therefore, any type of enclosure that prevents sparks can be utilized. If the motor insulation exceeds the limits of class B insulation, a heat exchanger must be installed. Figure 13 shows the maximum allowable insulation temperature for each motor insulation class.
Motor Insulation Class B F H
Maximum Allowable Insulation Temperature in oC 130 155 180
Figure 13: Maximum Allowable Insulation Temperature
Figure 14 shows motor enclosure cooling requirements. Motor Cooling The cooling of all motor components and lubricating oil (if required) should be by air. Liquid cooling is not acceptable. Where totally-enclosed machines utilize heat exchangers, closed-air circuitair cooled (CACA) exchangers must be provided and mounted on the motor. Top-mounted heat exchanger assemblies must have flanges that extend downward to overlap the motor enclosure on all sides by a minimum of 10 mm (0.4 in). When air/air heat exchangers require auxiliary fan cooling, shaft-mounted cooling fan or fans should be provided. Auxiliary motor-driven fans are not allowed for Saudi Aramco installations. Figure 14: Motor Enclosure Cooling Requirements
30
Figure 15 shows Saudi Aramco nameplate requirements.
Nameplate Construction
The nameplate(s)/rotation arrows must be 300 series stainless steel or monel. The nameplate(s)/rotation arrows must be securely fastened by pins of 300 series stainless steel, monel, or similar material. The nameplate(s)/rotation arrows must be located for easy visibility. Entries must be marked by etching, engraving, or by another permanent method of marking. The following is the minimum information that is required to be on machine nameplates:
Manufacturer's name, serial number or date code, and suitable
Nameplate Information
identification Horsepower output or kilowatt rating Time rating Temperature rise RPM at rated load Frequency Number of phases Voltage Rated-load amperes Code letter for kVA Buyer's purchase order number Year of manufacture Manufacturer's location Manufacturer's order reference number Anti-friction bearing number and manufacturer class, group, and division (explosion-proof motors, only) The following is a continuation of the minimum information that is required to be on motor nameplates:

Maximum ambient temperature Insulation system designation Rotor weight Total weight of motor Direction of rotation arrow
Figure 15: Nameplate Construction and Minimum Information Requirements
31
Figure 16 shows Saudi Aramco NEMA Frame induction motor technical requirements (excerpted from 17-SAMSS-503) for motors that are rated less than 0.746 KW (1 hp).
General Requirements
Motors must comply with NEMA MG-1, 1987 Rev.1, must be suitable for chemical/other severe duty applications. Motors for outdoor installation must be totally enclosed type. Motors for indoor installation must be of the drip-proof guarded type. The insulation system of the motor must be class B minimum. Enclosures and terminal housing must be cast iron or steel. Single phase motors must be provided with a built-in thermal protection device. Fans must be either metallic or high density, fiber filled, conductive polypropylene or phenolic. A corrosion-resistant grounding stud or pad must be provided in the terminal housing box.
Figure 16: NEMA Frame Induction Motor Technical Requirements for Motors that are Rated Less Than 0.746 KW (from 17-SAMSS-503)
32
Work Aid 1B:
Motor and Generator Winding, Wiring, and Space Heater Requirements
Figure 17 shows motor and generator winding requirements. Stator Winding The stator insulation system, including the leads, must consist of lowhygroscopic materials. The stator insulation system must have Class F insulation. The stator windings must be treated to withstand tropical conditions and the corrosive effects of industrial sulfurous atmospheres. Stator temperature must be monitored as follows: Motors that are rated 150 kW (200 hp) up to but not including 1300 kW (1750 hp) must have one RTD per phase. Motors that are rated 1300 kW (1750 hp) through 7500 kW (10,000 hp) must have two RTD's per phase. Motors that are rated above 7500 kW (10,000 hp) must have three RTD's per phase. The hottest reading RTD must be identified by the vendor during factory testing. The rotor windings of induction machines must be of the cage type and formed from copper, copper alloy, or aluminum bar. The rotor body of synchronous machines must be of the salient-pole type with the windings of insulated copper wire or strip that are treated to withstand tropical conditions. In addition to induction motor rotors, salient-pole rotors of synchronous motors may incorporate a copper starting cage to meet a desired torque characteristic. On squirrel-cage rotors, end-ring connections must be of high mechanical strength. Filler metals that are used should be resistant to attack by corrosive sulfurous gases. Copper alloy rotor construction should conform to American Welding Society AWS A5.8 and contain a minimum 40% silver. Copper-phosphorous bronze type fillers are technically unacceptable. The motor insulation system, including the leads, must consist of lowhygroscopic materials. The rotor insulation system must have Class F insulation.
Rotor Windings
Additional Rotor Construction Requirements Additional Rotor Construction Requirements
Figure 17: Motor and Generator Winding Construction Requirements
33
Figure 18 shows wiring and grounding requirements for Saudi Aramco motor and generator installations. Control and Wiring for auxiliary equipment must be moisture and heat resistant. Supply Leads Conductors must be made of copper and rated in accordance with the NEC for operation at 50oC ambient temperature. Minimum conductor size must be stranded 2.5 mm sq (No. 14 AWG). Conductors must be clearly and permanently identified with sleeve type PVC wire markers. All conductors that are passing through an internal baffle or partition that is within the motor enclosure must be protected by a bushing. Grounding Ground connections must accommodate the following minimum size of Connections grounding cable: Motor Rating kW (hp) 185 < 370 (250 < 500) 370 < 3360 (500 < 4500) 3360 & above (4500 & above) Cable Size mm2 (AWG/MCM) 70 (2/0) 120 (4/0) 185 (350)
Figure 18: Wiring and Grounding Requirements
Figure 19 shows Saudi Aramco motor and generator space heater design and construction requirements. Design and Construction Heaters must be installed in all motors that are rated 2.3 kV or higher. Motors that are rated less than 2.3 kV that are installed outdoors and used only as standby motors may also require heaters. Engineering drawings should be consulted. Motors must be equipped with space heaters that are completely wired, with leads that are brought out to a separate terminal box. Heaters with exposed elements are prohibited. Heater nameplate voltage must be twice the supply voltage that is indicated on the Data Schedule. Heaters must be suitable for supply voltages of 120 VAC, and they must be controlled by auxiliary contacts in the breaker.
Figure 19: Space Heater Design and Construction Requirements
34
Space heaters will maintain the temperature of the motor windings at approximately 5oC (9oF) above ambient. Surface temperatures of the space heater elements must not be greater than those surface temperatures that are shown in Figure 20. Area Classification Class I, Group C Class I, Group D Class II, Group E Class II, Group G Surface Temperature 160oC (320oF) 215oC (419oF) 200oC (392oF) 120oC (248oF)
Figure 20: Space Heater Temperature Requirements for Classified Areas Work Aid 1C: Motor Rating Requirements
Motors for Saudi Aramco installations must be selected in accordance with the table that is shown in Figure 21. Nom Sys Voltage 120 208 240 208 240 480 4160 4160 6900 13,800 13,800
(1) (2) (3) (4) (5)
Nameplate Voltage 115 200 230 200 230 460 4000 4000 6600 13,200 13,200
Phases 1 1 1 3 3 3 3 3 3 3 3
kW (hp) up to 0.25 (0.34) up to 0.25 (0.34) up to 0.25 (0.34) 0.18 (0.24) to 3.7 (5.0) 0.18 (0.24) to 7.5 (10.0) 0.18 (0.24) to 300 (400) 150 (200) to 3000 (4000) 500 (670) to 3000 (4000) 1000 (1340) to 6000 (8000) above 1000 (1340) above 10,000 (15,000)
Type ---Ind. Ind. Ind. Ind. Synch. Ind. Ind. Sync.
Notes 1 1 1 1 2 3 4
The 200 V rating is only for operation on 208 V system, and the 230 V rating is only for operation on 240 V system (see NEMA MG 1-14.33). Only for application at operating speeds of 1200 rpm and below. Above 1000 kW (1340 hp) the additional level of 6.6 kV is permitted. The use of a 6.6 kV motor plus unit transformer must be compared with a 13.2 kV motor on the basis of cost. Synchronous motors smaller than 10 000 kW (15 000 hp) are to be used only for operating speeds of 1200 rpm and below. Direct replacement of existing 2300 V Squirrel Cage Induction Motors is permitted. New installations of 2300 V Squirrel Cage Induction Motors with ratings from 185 kW (250 hp) to 1500 kW (2000 hp) are permitted if they are part of a 2400 V system expansion or addition which has been approved.
Figure 21: Motor Selection Table (from SAES-P-113)
35
Figure 22 shows a table of locked-rotor kVA "codes." The letter designators correspond to kVA per horsepower for ac motors.
Letter Designation A B C D E F G H J
kVA per hp 0 - 3.15 3.15 - 3.55 3.55 - 4.0 4.0 - 4.5 4.5 - 5.0 5.0 - 5.6 5.6 - 6.3 6.3 - 7.1 7.1 - 8.0
Letter Designation K L M N P R S T U V
kVA per hp 8.0 - 9.0 9.0 - 10.0 10.0 - 11.2 11.2 - 12.5 12.5 - 14.0 14.0 - 16.0 16.0 - 18.0 18.0 - 20.0 20.0 - 22.4 22.4 - and up
Figure 22: Ac Motor Locked-Rotor KVA per Horsepower (From NEMA MG-1)
Work Aid 1D:
Data Schedules
Figure 23 shows the data schedule from 17-SAMSS-503 that is used to order NEMA Frame motors.
36
DATA SCHEDULE FOR 17-SAMSS-503 NEMA FRAME MOTORS ----------------------------------------------------INFORMATION SUPPLIED BY BUYER Buyer's Quotation Request/Purchase Order No. _____________________ Buyer's B.I./J.O. No. ____________________________________________ Buyer's Line Item No. ____________________________________________ Driven Equipment: ________________________________________________ Motor Rating: KW ( hp) Synchronous Speed: _____________________ RPM NEMA Torque Design: ( ) "B"; ( ) Other (specify) ______________ ; Voltage ; Frequency 60 Hz; Phase Rotation Direction (Facing Motor Non-Drive End Opposite Shaft Extension) (Check one): ( ) clockwise; ( ) counterclockwise 10. ( ) Horizontal; ( )Vertical 11. Enclosure: ( ) TEFC; ( ) TENV; ( ) Explosion-proof; ( ) Other (specify) __________________ 12. ( ) Unclassified Area; ( ) Classified Area; Class ; Division ; Group 13. Shaft Type (Vertical Motors) ( ) Solid ( ) Other (specify) _________________ 14. Special Torque Requirements (if applicable) 15. Main Terminal Box, Conduit Hub Size: ----------------------------------------------------Approved: ______________ Date: ______________ Dwg. No. NTRevision No. ____________ Sheet 1 of 1 Figure 23: NEMA Frame Motor Data Schedule (from 17-SAMSS-503) 1. 2. 3. 4. 5. 6. 7. 8. 9.
37
Figure 24 shows the data schedule from 17-SAMSS-502 that is used to order induction motors. ATTACHMENT TO 17-SAMSS-502 (20 JUN 1995) INDUCTION MOTOR DATA SHEET - INFORMATION SUPPLIED BY BUYER
Buyer's Quote. Req./P.O. No. __________ B.I./J.O. No. ______ Line Item No. ______ Quantity _______ Driven Equip. ____________ Model ________ Ser. No. ________ Driven Eq't Data Sheet No. _________________ 1. 2. 6. 8. 9. 10. 11. Nameplate kW ____ ( ____ hp) Volts _____ 3. Phases __ 4. Hz ___ 5. Synch. RPM _____ Insul. Class ____ 7. Temp. Rise above 50 deg C by RTD _____ Mounting: Horizontal ___ Vertical ___ Bearing Type: Hydrodynamic ___ Anti-friction ___ Max. Sound Pressure Level _____ dB(A) Drive System: (A) Rotation Req'd by Driven Equip. Facing Motor Oppos. Dr. End: Clockwise ___ Counterclockwise ___ (B) Dir. Connected___ (C) Gear___ (D) Coupling Type ____ Enclosure: (A) TEFC ___ (B) CACA ___ (C) TEAAC ___ Tubes: Aluminum ___ Aluminum Alloy ___ Copper ___ Copper Alloy ___ Stainless Steel ___ (D) Explosion proof ___ Class ___ Div. ___ Group ___ Ignition Temperature ___ Site Conditions: (A) Onshore ___ (B) Offshore ___ (C) Dust ___ (D) Corrosive Conditions___ Terminal Box Sized for (A) Main motor leads: Shielded Cable Copper EPR___ XLPE___ Size_____mm sq/____AWG/MCM No./Phase___ Enter from: Above__ Below__ Side__ (R/L) Conduit Type_______; Size____; Number______ (B) C.T.'s for Differential Protection Yes ___ No ___ (C) Surge Protection Yes ___ No ___
12.
13. 14.
Figure 24: Induction Motor Data Schedule (from 17-SAMSS-502)
38
15.
16. 17. 18. 19. 20.
Tests (A) Performance Determination: Yes ___ No ___ (B) Temperature Test: Yes ___ No ___ (C) Miscellaneous Test: Yes ___ No ___ (D) Surge Test: Yes ___ No ___ (E) Conformance Test: Immersion ___ Spray ___ (F) Partial Discharge(13.2 kV only):Yes___ No___ Space Heater:Voltage ____Terminal Box: Conduits:____ EA NPT size:___Inch Provide Sight Oil Gauge: Yes:______ NO:_______ Vibration Detector Terminal Box: For Conduits:_____ EA NPT size :_____ Inch R.T.D Terminal Box: For Conduits:________ EA NPT Size :________ Inch Vendor to supply Speed-Torque and Speed-Current Curves Yes:______ No:_______
Approved by _____________________ Date _____________ ---------------------------------------------------PLANT NO. INDEX DRAWING NO. SH. NO.REV. NO. ---------------------------------------------------P 1 OF 2 ----------------------------------------------------
Figure 24: Induction Motor Data Schedule (from 17-SAMSS-502) (Cont'd)
39
Figure 25 shows the data schedule from 17-SAMSS-502 that is used to order synchronous motors.
ATTACHMENT TO 17-SAMSS-502 (20 JUN 1995) SYNCHRONOUS MOTOR DATA SHEET - INFORMATION SUPPLIED BY BUYER Buyer's Quot. Req./P.O. No. __________ B.I./J.O. No. _______ Line Item No. ______ Quantity _______ Driven Equip. ____________ Model ________ Ser. No. ________ Driven Eq't Data Sheet No. _________________ 1. 2. 6. 7. 8. 9. 10. 11. Nameplate kW ____ ( ____ hp) at Unity Power Factor Volts _____ 3. Phases __ 4. Hz ____ 5. Synch. RPM _____ Insul. Class: Motor ____; Exciter ____ Temp. Rise above 50 deg C by RTD _____ Mounting: Horizontal ___ Vertical ___ Bearing Type: Hydrodynamic ___ Anti-friction ___ Max. Sound Pressure Level _____ dB(A) Drive System: (A) Rotation Req'd by Driven Equip. Facing Motor Oppos. Dr. End: Clockwise ___ Counterclockwise ___ (B) Dir. Connected___ (C) Gear___ (D) Coupling Type ____ Enclosure: (A) TEFC ___ (B) CACA ___ (C) TEAAC ___ Tubes: Aluminum ___ Aluminum Alloy ___ Copper ___ Copper Alloy ___ Stainless Steel ___ (D) Explosionproof ___ Class ___ Div. ___ Group ___ Ignition Temperature ___ Site Conditions: (A) Onshore ___ (B) Offshore ___ (C)Dust ___ (D)Corrosive Conditions___ Terminal Box Sized for (A) Main motor leads: Shielded Cable Copper EPR___ XLPE___ Size_____mm/sq ____AWG/MCM No./Phase___ Enter from: Above__ Below__ Side__ (R/L) Conduit Type_______; Size____; Number______ (B) C.T.'s for Differential Protection Yes ___ No ___ (C) Surge Protection Yes ___ No ___
12.
13. 14.
Figure 25: Synchronous Motor Data Schedule (from 17-SAMSS-502)
40
15.
16. 17. 18. 19. 20. 21.
Tests (A) Performance Determination: Yes ___ No ___ (B) Temperature Test: Yes ___ No ___ (C) Miscellaneous Test: Yes ___ No ___ (D) Surge Test: Yes ___ No ___ (E) Conformance Test: Immersion ___ Spray ___ (F) Partial Discharge (13.2 kV only): Yes___ No___ Space Heater: Voltage_____; Terminal Box: Conduits:____EA NPT Size:____Inch Vibration Detector Terminal Box: For Conduits:_____ EA NPT Size:______ Inch R.T.D Terminal Box: For Conduits:_________ EA NPT Size :_________ Inch Exciter Terminal Box: Conduits: __________ EA NPT Size: __________ Inch Provide Sight Oil Gauge: Yes:_______ No:_______ Vendor To Supply Speed-Torque And Speed-Current Curves Yes:______ No:______
Approved by _____________________ Date _____________ ----------------------------------------------------PLANT NO. INDEX DRAWING NO. SH. NO. REV. NO. ----------------------------------------------------P 1 OF 2 -----------------------------------------------------
Figure 25: Synchronous Motor Data Schedule (from 17-SAMSS-502) (Cont'd)
41
WORK AID 2:
REFERENCES FOR EVALUATING MOTOR AND GENERATOR INSTALLATION AND TESTING
Unless stated otherwise, the information in this Work Aid contains combined excerpts from accepted industry practices and from the following resources: SAES-P-113, Motors and Generators 17-SAMSS-503, NEMA Frame Motors 17-SAMSS-502 Form Wound Induction and Synchronous Motors 17-SAMSS-510 Synchronous Generators GI-2.710 NEMA MG-1 Saudi Aramco Pre-Commissioning form P-019, NEMA Frame, Form Wound Induction and Synchronous Motors Work Aid 2A: Testing Requirements
The following are the minimum tests that are required for commissioning motors and generators: Measurement of winding resistance. No-load motoring readings of current, power, and nominal speed at rated voltage and frequency. Measurement of open-circuit voltage ratio on wound-rotor machines. High-potential (high-pot) test. Bearings/lube oil temperature measurement. When determined by the designer, the following tests should be performed: Performance determination Temperature tests Miscellaneous tests Surge tests
42
Work Aid 2B:
Information, Formulas, and Tables for Use in Evaluating the Results of Insulation Resistance (Megger) Tests
The results of all commissioning megger tests that are performed must be documented on the appropriate Saudi Aramco pre-commissioning form. For motors and generators, the acceptable values of insulation resistance only apply to insulation resistance readings that have been temperature corrected to 50oC. Before the temperature corrected insulation resistance readings are evaluated for acceptability or unacceptability, these values must be verified through use of the following formula and table: Rc = Kt Rt Where: Rc is the insulation resistance corrected to 50oC. Rt is the direct insulation resistance reading. Kt is the insulation resistance temperature coefficient from the following table: 10o .06 20o .12 30o .25 40o .5 50o 1 60o 2 70o 4 80o 8 90o 16 100o 32 110o 64
Winding Temp. Kt
The following are the minimum acceptable temperature corrected values of insulation resistance: Windings - Minimum acceptable Voltage 13,200 4,000 2,400 460 Min. IR (M) 15 5.5 3.5 1.5
Bearings - Minimum acceptable value is 200 k, but > 1 M is preferred. When the dielectric absorption ratio megger test is performed, the polarization index can be determined through use of the following equation:
43
Figure 26 provides insulation conditions for 60/30 second ratio results and for 10/1 minute ratio results.
Insulation Condition Dangerous Questionable Good Excellent
60/30 - Second Ratio -----1.0 to 1.25 1.4 to 1.6 Above 1.6
10/1 - Minute Ratio (Polarization Index) Less than 1 1.0 to 2 2 to 4 Above 4
Figure 26: Dielectric Absorption Ratio Chart
Work Aid 2C:
Information, Formulas, and Tables for Use in Evaluating the Results of Dc High-Pot Tests
For the commission dc high-pot test, the maximum test voltage must be determined as follows: Maximum Voltage = 75%{1.7(2 Rated Voltage + 1 kV)} Once the maximum test voltage is determined, the initial test voltage is calculated as follows: Initial Voltage = 33% (Maximum Voltage) A polarization index (PI) test is performed by applying an initial voltage step of about one-third of the recommended maximum voltage. The initial voltage step must be maintained at a constant level for ten minutes. The PI is calculated by dividing the one-minute leakage current by the tenminute leakage current. A PI value of 2.0 or less must be investigated. After the initial ten-minute test, the dc test voltage is increased in approximately ten uniform steps. Each step should have a one minute duration. The voltage is increased until the maximum recommended dc value is reached.
44
The following are the acceptable results of a high potential test: The micro-amperes leakage current should decrease in value during the initial ten minutes of the test at 33% test voltage. The micro-amperes leakage current should show a steady rise for the remainder of the test until the maximum test voltage is reached. A steady-state or rising value during the initial ten minutes of the test indicates poor insulation and, as a result, the insulation should be rejected. A sharp or an exponential rise in leakage current during the step voltage changes and prior to the application of the maximum test voltage also indicates poor insulation and, as a result, the insulation should be rejected. The dc high-pot test should be secured if one of the following situation occurs: The duration of the test has expired. A rapid rise in leakage current occurs. The polarization index < 1. The following are the characteristics of a satisfactory dc high-pot test: The leakage current gets smaller over time. The polarization index > 1. The leakage current increases on a straight line as voltage is increased. No "knee" is noticeable in the leakage current curve.
45
An example of dc high-pot test data is shown in Figure 27. Figure 27 shows typical results (both good and bad) of high-pot tests.
Figure 27: Typical Results of High-Pot Tests
Work Aid 2D:
Miscellaneous Tests/Checks
Rotating Rectifier Diode Check The exact values of diode resistance vary from one diode to another diode. For purposes of motor commissioning, the acceptable values of diode resistance are a low resistance in the forward direction and a high resistance in the reverse direction.
46
Air Gap Check The minimum acceptable values for radial air gap are shown in Figure 28. Motor Rating kW H.P. (NEMA) 801 - 1250 601 - 900 1250 - 1750 901 -1350 1751 - 2500 1350 - 2000 2501 - 4000 2001 - 2900 4001 and up 2901 and up Minimal Radial Air Gap mm (mil) 134 3.4 142 3.6 154 3.9 154 3.9 181 4.6
Figure 28: Radial Air Gap Values
Work Aid 2E: Phase Current
Acceptable Values for No Load Run Test Data
When the motor is started under loaded conditions, the maximum phase current values normally range from five to seven times the full load current of the motor. When the motor is started under no load conditions, the actual phase current values should be below this range and, in no case, can the values exceed this range. The running values of phase current should be approximately equal to and less than the full load nameplate current rating. Phase Voltage The individual phase voltages (A-B, B-C, and A-C) should be equal to the nameplate voltage rating 10%. Percent Voltage Unbalance Before the percent voltage unbalance can be evaluated, the percent voltage unbalance calculation must be verified through use of the following formula: %VU = 100(Vd / Vavg) Where: %VU is the percent voltage unbalance.
47
Vd is the maximum phase voltage deviation (VA-B, VB-C, or VA-C minus Vavg, whichever yields the highest deviation). Vavg is the average of the individual phase voltages. The maximum allowable percent voltage unbalance cannot exceed 1% for continuous operation. A percent voltage unbalance of 1.5% is acceptable for periods of time that are less than three minutes. Vibration Levels The maximum allowable vibration levels for horizontal motors that are equipped with proximity probes are as follows: Motor Speed (RPM) 3600 1800 1200 or less Max. Vibration Level (Mils) 2.0 2.5 3.0
The maximum allowable vibration level for vertical and for horizontal motors that are equipped with seismic velocity transducers is 4.6 mm/s. Winding Temperature The maximum winding temperature of a motor with Class B or with Class F insulation is 125oC at full load. This temperature is based on not exceeding the design temperature rise of Class B insulation when the ambient temperature is 50oC. The actual temperature that is measured during the no load run test should be significantly lower. Bearing Temperature The maximum allowable bearing temperature of a motor that is operating at full load is 90oC or is 40oC above the ambient temperature, whichever temperature is lower. The actual temperature that is measured during the no load run test should be significantly lower. % Ns When Excited The manufacturer's technical manual should be consulted for the minimum speed at which excitation should be applied to a given synchronous motor. If the manufacturer's technical manual is not available, the general thumb rule that is used is that excitation should not be applied until a synchronous motor reaches 97% to 98% of its rated synchronous speed.
Exciter Field Current The manufacturer's technical manual must be consulted to obtain the acceptable value of no load exciter field current for a given synchronous motor. Motor Field Current The manufacturer's technical manual must be consulted to obtain the acceptable value of no load motor field current for a given synchronous motor. Power Factor Synchronous motors are designed to operate at power factors that range from 1.0 to 0.8 leading. The manufacturer's technical manual must be consulted for the design power factor of a given synchronous motor. The actual power factor should be equal to the design power factor when the excitation control circuit is in automatic. Automatic is the normal mode of excitation control. Reactive Power (kVAR) The maximum reactive power that a synchronous motor can supply is dependent upon the power factor at which the motor is operating. The maximum reactive power at a given power factor can be calculated through use of the following equation: kVAR = kVA sin{cos-1(pf)} The actual reactive power that is supplied by the motor should be consistent with the load that is on the motor and the power factor at which the motor is operating. Work Aid 2F: Acceptable Values for Load Run Test Data
Inspection/Check of Motor Alignment The acceptable results for this inspection/check are that the inspection/check was satisfactorily completed. Phase Current When a motor is started under loaded conditions, the maximum phase current values should range from five to seven times the full load current of the motor. The running values of phase current should be approximately equal to each other and to the full load nameplate current rating.
49
Phase Voltage The individual phase voltages (A-B, B-C, and A-C) should be equal to the nameplate voltage rating 10%. Percent Voltage Unbalance Before the percent voltage unbalance can be evaluated, the percent voltage unbalance calculation must be verified through use of the following formula: %VU = 100(Vd / Vavg) Where: %VU is the percent voltage unbalance. Vd is the maximum phase voltage deviation (VA-B, VB-C, or VA-C minus Vavg, whichever yields the highest deviation). Vavg is the average of the individual phase voltages. The maximum allowable percent voltage unbalance cannot exceed 1% for continuous operation. A percent voltage unbalance of 1.5% is acceptable for periods of time that are less than three minutes. Vibration Levels The maximum allowable vibration levels for horizontal motors that are equipped with proximity probes are as follows: Motor Speed (RPM) 3600 1800 1200 or less Max. Vibration Level (Mils) 2.0 2.5 3.0
The maximum allowable vibration level for vertical and for horizontal motors that are equipped with seismic velocity transducers is 4.6 mm/s.
50
Winding Temperature The maximum winding temperature of a motor with Class F insulation is 125oC at full load. This temperature is based on not exceeding the design temperature rise of Class B insulation when the ambient temperature is 50oC. Bearing Temperature The maximum allowable bearing temperature of a motor that is operating at full load is 90oC or is 40oC above the ambient temperature, whichever temperature is lower. Voltage Dip on Start (%) The maximum voltage dip on start normally is limited to 15%. If an analysis of the other components of the power system shows that these components will not be adversely affected by a larger voltage dip, a voltage dip that is in excess of 15% may be permissible. Acceleration Time (Sec) The manufacturer's technical manual should be consulted to obtain the design acceleration time of a given motor. If the manufacturer's technical manual is not available, the general thumb rule is that most motors should accelerate to rated speed within ten seconds. % Ns When Excited The manufacturer's technical manual should be consulted for the minimum speed at which excitation should be applied to a given synchronous motor. If the manufacturer's technical manual is not available, the general thumb rule that is used is that excitation should not be applied until a synchronous motor reaches 97% to 98% of its rated synchronous speed. Exciter Field Current The manufacturer's technical manual must be consulted to obtain the acceptable value of full load exciter field current for a given synchronous motor. Motor Field Current The manufacturer's technical manual must be consulted to obtain the acceptable value of full load motor field current for a given synchronous motor.
51
Power Factor Synchronous motors are designed to operate at power factors that range from 0 to 0.8 leading. The manufacturer's technical manual must be consulted for the design power factor of a given synchronous motor. The actual power factor should be equal to the design power factor when the excitation control circuit is in automatic. Automatic is the normal mode of excitation control. Reactive Power (kVAR) The maximum reactive power that a synchronous motor can supply is dependent upon the power factor at which the motor is operating. The maximum reactive power at a given power factor can be calculated through use of the following equation: kVAR = kVA sin(cos-1(pf)) The actual reactive power that is supplied by the motor should be consistent with the load that is on the motor and the power factor at which the motor is operating. Work Aid 2G: Saudi Aramco Pre-Commissioning Form
Figure 29 shows the Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors, which provides a field installation checklist for motor installations. The pre-commissioning form has a broad checklist of visual and mechanical inspections, as well as the listed electrical and tests that are required for motor installations. Space is also provided on the form for test data.
52
Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors
Figure 29: Saudi Aramco Pre-Commissioning Form, P-019, NEMA Frame, Form Wound Induction and Synchronous Motors (Cont'd)
Work Aid 2H:
Excerpts from GI 2.710
The following is an excerpt from GI 2.710, New Construction Check List Example, that illustrates the overall checklist and sign-off for major pieces of electrical equipment. 3. Electrical Equipment All substations, power cable, electrical equipment, Construction Agency including lighting and wiring, to be checked for proper application, operation, and grounds. Distribution panels, switches properly identified, and all energization certificate requests signed.
Power Distribution Dept.
Project Inspection
Commissioning (Note 1)
71
Figure 30 shows an excerpt from GI 2.710, General Instruction Manual, that illustrates the inspections and tests that should be performed on major pieces of electrical equipment prior to the turnover of a facility.
Figure 30: GI 2.710 Excerpt
72
Figure 30: GI 2.710 Excerpt (Cont'd)
73
GLOSSARY accelerating torque The torque that is developed with rated power input between zero speed and full rated speed. American National Standards Institute. The maximum torque that is developed with rated power input. Closed Air Circuit Air-Cooled. A speed at which the amplitude of the vibration of a rotor that results from shaft transverse vibration reaches a maximum value.
ANSI breakdown torque CACA critical speed
dielectric absorption ratio The ratio of two timed insulation resistance readings (such as a 60-second reading that is divided by a 30-second reading). duty cycle The time interval occupied by a device on intermittent duty in starting, running, stopping, and idling. Explosion-proof motor. This type of motor is enclosed in a case that is capable of withstanding an explosion of a specified gas or vapor that may occur within it. EXd prevents the ignition of a specified gas or vapor surrounding the enclosure by sparks, flashes, or explosion of the gas or vapor within the enclosure. Non-sparking motor. The torque that is necessary to produce rated output at rated speed and at rated power input. International Electrotechnical Commission. The amount of opposition to the flow of electric current that is offered by an insulation. Ingress Protection. A bearing that supports the cylindrical journal of a shaft. The minimum torque that is developed by the motor at the instant that rated power is supplied to the terminal of the motor.
EXd
EXn full load torque
IEC insulation resistance
IP journal bearing locked-rotor torque
74
NEMA overload polarization index
National Electrical Manufacturer's Association. Operation of equipment in excess of normal, full load rating. The ratio of a ten-minute insulation resistance reading divided by a one-minute insulation resistance reading. The distance between the rotor windings and stator windings of a motor. A commutator motor in which the field circuit and armature circuit are connected in series. A bearing with a cylindrical inner surface in which the journal of a rotor shaft rotates. The density of sound power at a point away from the source. This density of sound power is expressed in watts per square meter. Sound power that is radiated by a source may be derived by integration of the intensity over an enclosed hypothetical surface of measurement. A weighted measure of the amount of noise that is produced by a machine at a given point.
radial air gap
series motor
sleeve bearing
sound intensity
sound level
sound pressure level (SPL) The level of pressure in the sound-conducting medium that results from the sound intensity at the concerned point. sound power (SWL) A property of the noise that is produced by a machine that is independent of the environmental conditions or the distance from the machine. A dc motor in which the field circuit and armature circuit are connected in parallel. Totally Enclosed Fan-Cooled. An induction motor in which the secondary circuit consists of polyphase windings or coils whose terminals are either shortcircuited or closed through suitable circuits. A location in which ignitable concentrations of flammable gases or vapors can exist under normal conditions.
75
shunt-wound motor
TEFC wound-rotor induction motor
zone 1
zone 2
A location in which volatile flammable liquids or flammable gases are handled, processed, or used but in which the liquids, vapors, or gases will normally be confined within closed containers or closed systems from which they can escape only in case of accidental rupture or breakdown.
76

Commissioning Motors and Generators

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Commissioning Motors and Generators

Caricato da

Copyright:

Formati disponibili

Engineering Encyclopedia

Saudi Aramco DeskTop Standards