PDVSA

ENGINEERING DESIGN MANUAL

VOLUME 4I ENGINEERING SPECIFICATION

PDVSA N

TITULO

N278

SPECIAL PURPOSE APPLICATION OF API 546 BRUSHLESS SYNCHRONOUS MACHINES 500 KVA AND LARGER

0
REV. APPD.

SEP.02
FECHA

APPROVED
DESCRIPCION DATE

15

L.T.

Y.K.
APPD. DATE

R.R.
APPD.

PAG. REV. APPD.

Youhad Kerbaje

SEP.02

Ral Rivero

SEP.02

E PDVSA, 1983

ESPECIALIST

ENGINEERING SPECIFICATION

PDVSA N278 REVISION FECHA

PDVSA
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SPECIAL PURPOSE APPLICATION OF API 546 BRUSHLESS SYNCHRONOUS MACHINES 500 KVA AND LARGER
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Index
1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 BASIC DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 2.2 2.3 2.4 3.1 3.2 3.3 3.4 3.5 3.6 4.1 4.2 4.3 4.4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Insulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Winding Temperature Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing Temperature Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Space Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screens and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarms and Control Devices for Motor Protection . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparation for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3
3 4 4 4

3 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
8 9 9 9 9 10

4 INSPECTION, TESTING AND PREPARATION FOR SHIPMENT . .

10
10 10 12 13

5 GUARANTEE AND WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 VENDORS DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 6.2 Proposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contract Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 13
13 14

ENGINEERING SPECIFICATION

PDVSA N278 REVISION FECHA

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SPECIAL PURPOSE APPLICATION OF API 546 BRUSHLESS SYNCHRONOUS MACHINES 500 KVA AND LARGER
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Introduction
Purpose The purpose of this Practice is to provide a specification for purchase (including design, fabrication, inspection, testing, and shipment) of brushless synchronous machines for special purpose application in the process industries. Scope The purpose of this Practice is to provide a specification for purchase (including design, fabrication, inspection, testing, and shipment) of brushless synchronous machines (motors and generators) for special purpose application in the process industries.

References
All machines shall be designed, constructed, and tested in accordance with the latest edition, or the edition specified, of the following industry standards and references. These standards shall be considered an integral part of this Practice. Short titles will be used herein when appropriate. Industry Standards S American National Standards Institute (ANSI) ANSI/NEMA MG 1 Motors and Generators S American Petroleum Institute (API) API 546 Brushless Synchronous Machines 500 kVA and Larger, Second Edition API 614 Lubrication, Shaft Sealing, and Control Oil Systems for Special Purpose Applications S Institute of Electrical and Electronics Engineers (IEEE) IEEE 115 Standard Test Procedure for Synchronous Machines IEEE 522 Guide for Testing TurntoTurn Insulation on FormWound Stator Coils for AlternatingCurrent Rotating Electric Machines S International Electrotechnical Commission (IEC) IEC 894 Guide for Test Procedure for the Measurement of Loss Tangent of Coils and Bars for Machine Windings S Steel Structures Painting Council (SSPC) SSPC SP 6 Commercial Blast Cleaning

Modifications to API 546

Requirements for brushless synchronous machines shall be in accordance with API 546, except as modified by this Practice.

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SPECIAL PURPOSE APPLICATION OF API 546 BRUSHLESS SYNCHRONOUS MACHINES 500 KVA AND LARGER
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Requirements of API 546 that are not modified remain applicable as written.

Definitions
The following terms are used by this Practice to modify the requirements of API 546: Add: This term is used to introduce requirement(s) that is/are additional to the requirements in API 546 Decision: This term is used to provide a decision for a bulleted paragraph in API 546 Delete: This term is used to introduce deletion of requirement(s) in API 546 Modify to read: This term is used to introduce a requirement that modifies a requirement in API 546 The paragraph numbers and associated headings used below are those used in API 546. This Practice does not modify all paragraphs in API 546. Therefore, the paragraph numbers in this Practice may not be sequential.

GENERAL
Modify to read Any conflicts between the reference documents shall be identified in writing to the Purchaser for resolution. When resolving conflicts, the following order of precedence shall apply: S S S S Purchase Order Data Sheet (Motor / Generator) This Practice Referenced Documents

BASIC DESIGN
2.1
2.1.3

General
Modify to read: Unless specified otherwise on the Data Sheet (Motor / Generator), the A weighted maximum sound pressure level of the machine shall not exceed 85 dBA at any location at a reference distance of 1 meter determined in accordance with ANSI/NEMA MG1 Part 9 with machine operating at full voltage, rated frequency, and no load.

ENGINEERING SPECIFICATION

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SPECIAL PURPOSE APPLICATION OF API 546 BRUSHLESS SYNCHRONOUS MACHINES 500 KVA AND LARGER
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2.1.15

Add Machines of the same rating, mounting and characteristics shall be interchangeable.

2.2
2.2.5.2.c

Electrical Design
Add: If no value is specified on the Data Sheet (Motor / Generator), the motor shall be capable of accelerating the connected load to running speed with 80 percent of the rated voltage on the motor terminals.

2.2.7.1

Add: Inverter fed motors shall be designed to perform with harmonics generated from static converters/inverters used for adjustable speed drive system. It will be Manufacturers responsibility to coordinate with the supplier of the adjustable speed drive system to obtain all necessary harmonics data and design the motor for the specified operation. Special attention shall be paid to avoid the conditions stated in API 546, article 1.1.1, Note 3.

2.3
2.3.1.7

Insulation System
Add: The insulation system shall be capable of withstanding the surge test specified in Figure 1 of IEEE 522.

2.4
2.4.1 2.4.1.1.c

Mechanical Design
Enclosures Decision: AISI 300 series stainless steel shall be used for all enclosure fastening devices.

2.4.1.2.1

Decision: Unless otherwise specified on the Data Sheet (Motor / Generator), the motor enclosure shall be TotallyEnclosed AirAir Cooled (TEAAC).

2.4.1.2.3.h Add: Where TEAAC enclosures are specified, the cooling air for the heat exchanger shall be supplied either by a shaft driven fan (preferred method) or by an externally mounted auxiliary blower. For special purpose motors, external auxiliary blowers,

ENGINEERING SPECIFICATION

PDVSA N278 REVISION FECHA

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SPECIAL PURPOSE APPLICATION OF API 546 BRUSHLESS SYNCHRONOUS MACHINES 500 KVA AND LARGER
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if supplied, shall be furnished in a 100% redundant, configuration. Lowvoltage motors shall be designed and constructed according to IEEE 841. 2.4.1.2.4.b Decision: Unless specified otherwise on the Data Sheet (Motor / Generator), totally enclosed wateraircooled (TEWAC) motors shall have a minimum of two (2), 100% capacity, water coolers. 2.4.1.2.4.c Modify to read: Unless specified otherwise on the Data Sheet (Motor / Generator), the water box connections shall be located opposite the main terminal box. The materials and construction of the cooler and cleaning requirements shall be developed jointly by the Purchaser and the Vendor. Leak detection shall conform to manufacturer standards. For double tube coolers, detectors shall sense inner tube leakage and, when specified on Data Sheet (Motor / Generator), outer tube leakage. 2.4.1.2.4.e Decision: Coolers mounted above the motor windings shall be of double tube construction. 2.4.1.2.4.h Decision: Air temperature sensors to sense air temperature into and out of the coolers shall be RTD type unless specified otherwise on the Data Sheet (Motor / Generator). 2.4.2 2.4.2.6 Frame and Mounting Plates Modify to read: If the motor is to be installed on a baseplate, this baseplate is to be supplied by the driven equipment supplier. If not, then soleplates shall be supplied by the motor manufacturer. When the new machine replaces an existing one, Purchaser shall specify the pertinent data (i.e., installation details, footprint and other dimensional drawings). 2.4.2.7.4 Modify to read: Epoxy grout shall be used for mounting. The Vendor shall blastclean in accordance with ISO 8501 Grade Sa2 (SSPC SP 6), all grout contact surfaces of the mounting plates and coat those surfaces with a rust preventative that can be removed with solvent. Purchaser will clean and blast the surfaces to near white metal and apply a grout compatible primer in the field. Note: A compatible primer is required to achieve full bond strength, but epoxy primers have a limited life after application. 2.4.2.14 Decision: When major components or multiple motors can utilize the same lifting device, one set of special lifting devices shall be provided, unless additional sets are specifically indicated on the Data Sheet (Motor / Generator).

ENGINEERING SPECIFICATION

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SPECIAL PURPOSE APPLICATION OF API 546 BRUSHLESS SYNCHRONOUS MACHINES 500 KVA AND LARGER
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2.4.3 2.4.3.4

Frame Connections Modify to read: Piping flanges shall conform to ASME B16.1 or B16.5 as applicable, except as specified in 2.4.3.5.1 and 2.4.3.5.2.

2.4.3.10

Add: All conduits shall be aluminum conduits. Final terminations to device terminal boxes and devices may be liquidtight flexible conduits, 0.6 m maximum length with approved fittings. All power and control wiring within the confines of the motor shall be heat, moisture, and abrasiveresistant. All wiring shall be stranded copper.

2.4.5 2.4.5.1.1

Rotating Element Modify to read: The rotating element shall be designed and constructed to withstand the starting duties specified in 2.2.6 with a fatigue life of at least 5000 fullvoltage starts or as specified by the Purchaser.

2.4.5.2.2

Modify to read: Machines with fabricatedbar amortisseur windings shall be furnished with copper and/or copper alloy bars and end rings. Aluminum is not acceptable.

2.4.6 2.4.6.2.3

Dynamics Decision: For motors driving reciprocating loads, or those applied to adjustable speed drives, a steady state and transient torsional and stress analysis of the motor and driven equipment shall be performed by the driven equipment supplier.

2.4.6.3.4

Decision: A balanced halfcoupling furnished by the driven equipment supplier shall be mounted on the rotor and the rotor balance shall be rechecked.

2.4.7 2.4.7.8

Bearings and Bearing Housings Add: Each motor shall be provided with both bearings electrically insulated from the frame and bearing housing. Insulation resistance from the frame shall not be less than one (1) megohm. Warning nameplates reading Insulated Bearing shall be mounted on or near all motor bearings that are electrically insulated from the motor frame. Terminal facilities shall be provided to permit direct resistance measurements for testing of the bearing insulation.

ENGINEERING SPECIFICATION

PDVSA N278 REVISION FECHA

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SPECIAL PURPOSE APPLICATION OF API 546 BRUSHLESS SYNCHRONOUS MACHINES 500 KVA AND LARGER
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2.4.7.12

Decision: Constant level sight feed oilers shall be provided.

2.4.7.21

Decision: For common or circulating lube oil systems, seals shall be constructed so that a purge gas can be introduced.

2.4.8 2.4.8.3

Lubrication Decision: Oil rings/flingers shall be provided.

2.4.8.4

Modify to read: When a lubrication system is furnished with the driven equipment, this lube oil system shall also supply the motor if the motor requires pressurized or circulating lubrication.

2.4.8.8.2

Modify to read: Oil return lines shall be sized to run no more than half full and shall be arranged to ensure good drainage (recognizing the possibility of foaming conditions). Horizontal runs shall slope continuously, at least 1/2 inch per foot (42 millimeters per meter), toward the reservoir. If possible, laterals (not more than one in any transverse plane) shall enter drain headers at 45 degree angles in the direction of the flow. Nonconsumable backup rings and sleevetype joints shall not be used. Oil filters shall be capable of withstanding the specified oil supply header pressure. Pressure piping downstream of oil filters shall be free from internal obstructions that could accumulate dirt. Unless otherwise specified, oil supply piping and tubing, including fittings (excluding slipon flanges), shall be AISI 300 series stainless steel.

2.4.8.8.7

Decision: Duplex filters with a constantflow transfer valve shall be provided.

2.4.8.8.8

Decision: Unless otherwise specified, an electric immersion heater shall be supplied if deemed necessary according to the ambient minimum temperature.

2.4.9 2.4.9.4

End Play and Couplings Decision: Unless otherwise specified, the motor half coupling shall be mounted on the motor shaft with a cylindrical fit.

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SPECIAL PURPOSE APPLICATION OF API 546 BRUSHLESS SYNCHRONOUS MACHINES 500 KVA AND LARGER
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2.4.9.5

Decision: Testing with the contract coupling hub is required for twopole motors 2000 hp and larger.

2.4.11 2.4.11.1

Nameplates and Rotation Arrows Decision: Nameplates and rotation arrows shall be of AISI 300 series stainless steel.

2.4.11.3.b Add: An engraved caution nameplate shall be provided on the front of the space heater terminal box stating CAUTION: SPACE HEATERS MAY BE ENERGIZED. The nameplate shall be black engraving on a yellow background. 2.4.11.4 Modify to read: The Purchasers identification information, including project number, purchase order number and equipment number, shall be stamped on a separate nameplate.

ACCESSORIES
3.1
3.1.1

Terminal Boxes
Decision: Oversized boxes to accommodate wire size and any other options specified on Data Sheet (Motor / Generator) shall be provided.

3.1.6.a

Decision: If the terminal box contains accessories (e.g., current transformers, surge arresters, etc.), thermal insulation shall be provided.

3.1.6.b

Decision: If the terminal box contains accessories (e.g., current transformers, surge arresters, etc.), space heaters shall be provided.

3.1.6.f

Decision: If the box contains accessories (e.g., differential CTs, surge arresters, etc.), removable links shall be provided.

3.1.6.g

Decision: If shielded cables are specified, adequate space for termination shall be provided.

ENGINEERING SPECIFICATION

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SPECIAL PURPOSE APPLICATION OF API 546 BRUSHLESS SYNCHRONOUS MACHINES 500 KVA AND LARGER
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3.1.8

Decision: Secondary leads shall be provided.

3.1.11

Modify to read: Terminal boxes shall be provided for each class of sensor or auxiliary devices. Separate terminal boxes, for example, shall be provided for vibration sensors, temperature sensors and space heaters. All wiring external to the machine shall be in rigid metallic conduit, with the exception that the final 0.6 m may be in flex conduit to facilitate connection to end devices.

3.2
3.2.1

Winding Temperature Detectors

Decision: Winding temperature detectors shall be provided of the type specified on the Data Sheet (Motor / Generator).

3.3
3.3.1

Bearing Temperature Detectors

Decision: Bearing temperature detectors shall be provided on motors having hydrodynamic radial and, if installed, hydrodynamic thrust bearings.

3.4
3.4.1

Space Heaters
Decision: Space heaters shall be provided in the motor enclosure.

3.4.3

Modify to read: Space heaters shall be arranged so that heat is radiated from both sides to provide uniform heating of the stator windings. The heaters shall maintain the temperature of the motor windings at approximately 5 C above the ambient temperature. The surface temperature of the heater elements shall not be greater than 80 percent of the autoignition temperature, as specified on the Data Sheet (Motor / Generator), or 200 C, whichever is less.

3.5
3.5.4

Screens and Filters

Decision: Filters shall be provided for WPII motors. Entire filter element and support assembly shall be constructed of AISI 300 series stainless steel.

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3.5.5

Modify to read: A differential pressuresensing device to measure pressure drop across the filters shall be provided and shall be accessible from the exterior of the motor housing.

3.6
3.6.1

Alarms and Control Devices for Motor Protection

Modify to read: Alarms and control devices shall be equipped with singlepole, doublethrow switches with minimum ratings of 10 Amps at 120 Volts AC and 3 Amps at 125 Volts DC.

3.6.4.2

Add: Each synchronous motor shall be equipped with a brushless excitation system consisting of a three phase alternating current (AC) exciter with revolving armature and stationary field, threephase bridge rectifier, motor field starting and discharge resistor, and necessary static control modules to provide full function excitation control. The brushless excitation system shall be totally enclosed forcecooled utilizing air ducted from the main motor air stream. Static control devices shall require no planned onsite adjustment for changes in ambient conditions or repeated use of components. The control modules shall be replaceable as complete components requiring no contingent modifications of wiring or circuitry and no on site tuning or adjustment. Rotating control modules and devices that are mounted on the shaft and rotor shall be readily accessible through easily removable covers or plates and shall not require extensive disassembly of the motor housing for removal. The excitation system shall be provided with an automatic system to detect abnormalities, as specified on the Data Sheet.

INSPECTION, TESTING AND PREPARATION FOR SHIPMENT

4.1
4.1.1

General
Decision: The Vendor shall provide 10 working days advance notice to the Purchaser before each inspection or test, except for the final test which requires 15 working days advance notice.

4.2
4.2.1 4.2.1.1.a

Inspection
General Decision:

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Certification of materials shall be kept available. 4.2.1.1.e Decision: Final assembly maintenance and running clearances data shall be kept available. 4.2.1.2 Decision: Parts shall not be painted until the inspection of the parts is complete. 4.2.1.3 Decision: Ultrasonic inspection shall be performed on all forged components. Magnetic particle and liquid penetrant inspection shall be performed on all shaft welds. 4.2.2 4.2.2.1 Material Inspection Modify to read: When radiographic, ultrasonic, magnetic particle, or liquid penetrant inspection of welds or materials is required or specified, the tests are to be conducted per the applicable sections of ASTM and ASME Standards. 4.2.2.2 4.2.2.3 4.2.2.4 4.2.2.5 4.2.3 4.2.3.2 Delete Delete Delete Delete Inspection Decision: For all machines having circulating pressure oil systems, the oil system furnished shall meet the cleanliness requirements of API 614. 4.2.3.3 Decision: The Purchaser may inspect for cleanliness the equipment and all piping and appurtenances furnished by or through the Vendor before full assembly. 4.2.3.4 Decision: The hardness of parts, welds, and heataffected zones shall be verified as being within the allowable values by testing of the parts, welds or zones. 4.2.3.5 Modify to read: The Vendor shall submit their quality program to the Purchaser for review.

ENGINEERING SPECIFICATION

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SPECIAL PURPOSE APPLICATION OF API 546 BRUSHLESS SYNCHRONOUS MACHINES 500 KVA AND LARGER
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4.2.3.6

Decision: The tests listed in 4.2.3.6 shall be performed.

4.3
4.3.1 4.3.1.1

Final Testing
General Modify to read: The Purchaser reserves the right to observe the manufacturing, testing, dismantling, inspection, and reassembly of the equipment.

4.3.2 4.3.2.d

Routine Test Decision: The preferred values listed in Table 5 shall be used.

4.3.4 4.3.4.1

Stator Tests Decision: Stator core test shall be performed.

4.3.4.3

Modify to Read: A power factor tipup test (tandelta) shall be performed on stator windings rated 6 kV and above in accordance with IEC 894. The acceptance criteria shall be mutually agreed upon between the Vendor and Purchaser.

4.3.4.4

Decision: Water immersion or spray test shall be performed on all motor stators equipped with sealed insulation systems.

4.3.5 4.3.5.1.1

Special Tests Decision: Complete test shall be performed on one motor of each group of identically designed and manufactured motors.

4.3.5.1.2

Decision: Bearing shall be disassembled and visually inspected per paragraph 4.3.2.1i, but dimensional checks are not required. There shall be no evidence of babbitt flow or smearing and no metal transfer between the shaft and bearing. Where the lubricant is accessible, its condition shall be visually examined after the run.

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4.3.5.1.3

Decision: DC high potential testing shall be performed on motors rated 6 kV and above.

4.3.5.2.1

Decision: Heat run test is required as a part of the Complete Test specified in 4.3.5.1.1.

4.3.5.4

Decision: Unbalance response test shall be performed for twopole motors 1000 hp and above and when motors are applied with adjustable speed drives.

4.4
4.4.3.6

Preparation for Shipment

Decision: Shipping skid shall be provided.

GUARANTEE AND WARRANTY

Modify to read: See other purchase documents for Guarantee and Warranty details.

VENDORS DATA
6.1
6.1.4.a

Proposal
Decision: The motors average torque versus speed during starting at rated voltage and at 80 percent rated voltage shall be supplied.

6.1.4.b

Decision: The motors current versus speed during starting at rated voltage and at 80 percent rated voltage shall be supplied.

6.1.4.g

Decision: The power factor and guaranteed efficiencies at 1/4, 1/2, 3/4, and full load (calculated in accordance with the IEEE 112 method used during the test) shall be supplied.

6.1.4.h

Decision: When the motor is driving a load having a variable torque during each revolution of the motor shaft, the Vendor shall provide: the maximum current variation under actual operating conditions, the calculated motor efficiency under these conditions based on an expected minimum efficiency, and the method of calculating the efficiency under operating conditions.

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6.1.16

Decision: Vendor shall provide an outline of all necessary special weather and winterizing protection required for the motor.

6.1.18

Decision: Vendor shall provide rate schedules for an erection supervisor.

6.2
6.2.2 6.2.2.1

Contract Data
Drawing and Data Requirements Modify to read: Vendor to provide one (1) reproducible set of drawings plus the specified number of copies of all documentation and operating manuals as indicated on the Data Sheet (Motor / Generator). Format for reproducibles shall be CAD convertible .DXF electronic format, unless the Vendor specifies otherwise in the proposal.

6.2.2.2

Vendor drawing and data requirements are given on the following table: A
With Bid X X X X X X

D
As Built

DESCRIPTION
(The following items are described in more detail in API 541) Dimensioned outline drawings with major and minor connections Foundation loading diagrams Schematic wiring diagrams Flow diagrams Detail drawings and crosssectional drawings Erection/assembly drawings Calculations torsional/lateral response Predicted performance curves Vendors data reports Performance test reports Installation, maintenance, and operating instructions Recommended spare parts list

For Final Review Certified X X X X X X X X X X X X X X X X X

X X X(1)

A. B. C.

Bidder shall furnish these documents with proposal. Vendor shall furnish these documents for Purchasers review and shall receive Purchasers authorization prior to proceeding with fabrication. Vendor shall furnish these documents as part of the final certified document submittal

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6.2.3 6.2.4 6.2.5 6.2.5.1 6.2.5.2

Delete Delete Documentation Content (Add) All engineering data provided for this equipment shall represent the actual equipment specified and ordered. Typical drawings are acceptable only if they are revised to specifically identify the equipment, accessories, wiring and dimensions being furnished.