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PDVSA N TITULO

REV. FECHA DESCRIPCION PAG. REV. APPD. APPD.

APPD. DATEAPPD.DATE

VOLUME 4I

E PDVSA, 1983

N278 SPECIAL PURPOSE APPLICATION OF API 546

BRUSHLESS SYNCHRONOUS MACHINES 500 KVA

AND LARGER

APPROVED

Youhad Kerbaje Ral RiveroSEP.02 SEP.02

ENGINEERING SPECIFICATION

SEP.02 L.T.0 15 Y.K. R.R.

ENGINEERING DESIGN MANUAL

ESPECIALIST

PDVSA
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SPECIAL PURPOSE APPLICATION OF API 546BRUSHLESS SYNCHRONOUS MACHINES

500 KVA AND LARGER

SEP.020

PDVSA N278

Pgina 1

.Men Principal Indice manual Indice volumen Indice norma

PDVSA

Index

1 GENERAL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 BASIC DESIGN 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 General 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Electrical Design 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Insulation System 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Mechanical Design 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 ACCESSORIES 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Terminal Boxes 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Winding Temperature Detectors 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 Bearing Temperature Detectors 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Space Heaters 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Screens and Filters 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Alarms and Control Devices for Motor Protection 10. . . . . . . . . . . . . . . . . . . .

4 INSPECTION, TESTING AND PREPARATION FOR SHIPMENT 10. .

4.1 General 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Inspection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Final Testing 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Preparation for Shipment 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 GUARANTEE AND WARRANTY 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 VENDORS DATA 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Proposal 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Contract Data 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Introduction

Purpose

The purpose of this Practice is to provide a specification for purchase (includingdesign, fabrication, inspection, testing, and shipment) of brushless synchronousmachines for special purpose application in the process industries.

Scope

The purpose of this Practice is to provide a specification for purchase (includingdesign, fabrication, inspection, testing, and shipment) of brushless synchronousmachines (motors and generators) for special purpose application in the processindustries.

References

All machines shall be designed, constructed, and tested in accordance with thelatest edition, or the edition specified, of the following industry standards andreferences. 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, SecondEdition

API 614 Lubrication, Shaft Sealing, and Control Oil Systems for SpecialPurpose Applications

S Institute of Electrical and Electronics Engineers (IEEE)

IEEE 115Standard Test Procedure for Synchronous Machines

IEEE 522 Guide for Testing TurntoTurn Insulation on FormWoundStator Coils for AlternatingCurrent Rotating Electric Machines

SInternational 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 withAPI 546, except as modified by this Practice.
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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 API546:

Add: This term is used to introduce requirement(s) that is/are additional to therequirements in API 546

Decision: This term is used to provide a decision for a bulleted paragraph in API546

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 arequirement in API 546

The paragraph numbers and associated headings used below are those used inAPI 546. This Practice does not modify all paragraphs in API 546. Therefore, theparagraph numbers in this Practice may not be sequential.

1 GENERALModify to read

Any conflicts between the reference documents shall be identified in writing to thePurchaser for resolution. When resolving conflicts, the following order ofprecedence shall apply:

S Purchase Order

S Data Sheet (Motor/Generator)

S This Practice

S Referenced Documents

2 BASIC DESIGN

2.1 General

2.1.3 Modify to read:

Unless specified otherwise on the Data Sheet (Motor / Generator), the Aweighted maximum sound pressure level of the machine shall not exceed 85 dBAat any location at a reference distance of 1 meter determined in accordance withANSI/NEMA MG1 Part 9with machine operating at full voltage, rated frequency,and no load.
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2.1.15 Add

Machines of the same rating, mounting and characteristics shall beinterchangeable.

2.2 Electrical Design

2.2.5.2.c Add:

If no value is specified on the Data Sheet (Motor/Generator), the motor shallbe capable of accelerating the connected load to running speed with 80 percentof the rated voltage on the motor terminals.

2.2.7.1 Add:

Inverter fed motors shall be designed to perform with harmonics generated fromstatic converters/inverters used for adjustable speed drive system. It will beManufacturers responsibility to coordinate with the supplier of the adjustablespeed drive system to obtain all necessary harmonics data and design the motorfor the specified operation. Special attention shall be paid to avoid the conditionsstated in API 546, article 1.1.1, Note 3.

2.3 Insulation System

2.3.1.7 Add:

The insulation system shall be capable of withstanding the surge test specified inFigure 1 of IEEE 522.

2.4 Mechanical Design

2.4.1 Enclosures

2.4.1.1.c 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 motorenclosure shall be TotallyEnclosed AirAir Cooled (TEAAC).

2.4.1.2.3.h Add:

Where TEAAC enclosures are specified, the cooling air for the heat exchangershall be supplied either by a shaft driven fan (preferred method) or by an externallymounted auxiliary blower. For special purpose motors, external auxiliary blowers,
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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), totallyenclosed 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 boxconnections shall be located opposite the main terminal box. The materials andconstruction of the cooler and cleaning requirements shall be developed jointly bythe Purchaser and the Vendor. Leak detection shall conform to manufacturerstandards. 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 shallbe RTD type unless specified otherwise on the Data Sheet (Motor/Generator).

2.4.2 Frame and Mounting Plates

2.4.2.6 Modify to read:If the motor is to be installed on a baseplate, this baseplate is to be supplied bythe driven equipment supplier. If not, then soleplates shall be supplied by themotor manufacturer. When the new machine replaces an existing one, Purchasershall specify the pertinent data (i.e., installation details, footprint and otherdimensional drawings).

2.4.2.7.4 Modify to read:

Epoxy grout shall be used for mounting. The Vendor shall blastclean inaccordance with ISO 8501 Grade Sa2 (SSPC SP 6), all grout contact surfaces ofthe mounting plates and coat those surfaces with a rust preventative that can beremoved with solvent. Purchaser will clean and blast the surfaces to near whitemetal and apply a grout compatible primer in the field. Note: A compatibleprimer is required to achieve full bond strength, but epoxy primers have alimited 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 arespecifically indicated on the Data Sheet (Motor / Generator).
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2.4.3 Frame Connections

2.4.3.4 Modify to read:

Piping flanges shall conform to ASME B16.1 or B16.5 as applicable, except asspecified 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 terminalboxes and devices may be liquidtight flexible conduits, 0.6 m maximum lengthwith approved fittings. All power and control wiring within the confines of the motorshall be heat, moisture, and abrasiveresistant. All wiring shall be strandedcopper.

2.4.5 Rotating Element


The rotating element shall be designed and constructed to withstand the startingduties specified in 2.2.6 with a fatigue life of at least 5000 fullvoltage starts or asspecified by the Purchaser.


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

2.4.6 Dynamics

2.4.6.2.3 Decision:

For motors driving reciprocating loads, or those applied to adjustable speeddrives, a steady state and transient torsional and stress analysis of the motor anddriven 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 bemounted on the rotor and the rotor balance shall be rechecked.

2.4.7 Bearings and Bearing Housings

2.4.7.8 Add:

Each motor shall be provided with both bearings electrically insulated from theframe and bearing housing. Insulation resistance from the frame shall not be lessthan one (1) megohm. Warning nameplates reading Insulated Bearing shall bemounted on or near all motor bearings that are electrically insulated from themotor frame. Terminal facilities shall be provided to permit direct resistancemeasurements for testing of the bearing insulation.

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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 apurge gas can be introduced.

2.4.8 Lubrication

2.4.8.3 Decision:

Oil rings/flingers shall be provided.


When a lubrication system is furnished with the driven equipment, this lube oilsystem shall also supply the motor if the motor requires pressurized or circulatinglubrication.


Oil return lines shall be sized to run no more than half full and shall be arrangedto ensure good drainage (recognizing the possibility of foaming conditions).Horizontal runs shall slope continuously, at least 1/2 inch per foot (42 millimetersper 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 directionof the flow. Nonconsumable backup rings and sleevetype joints shall not beused. Oil filters shall be capable of withstanding the specified oil supply headerpressure. Pressure piping downstream of oil filters shall be free from internalobstructions that could accumulate dirt. Unless otherwise specified, oil supplypiping and tubing, including fittings (excluding slipon flanges), shall be AISI 300series 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 ifdeemed necessary according to the ambient minimum temperature.

2.4.9 End Play and Couplings

2.4.9.4 Decision:

Unless otherwise specified, the motor half coupling shall be mounted on the motorshaft with a cylindrical fit.

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2.4.9.5 Decision:

Testing with the contract coupling hub is required for twopole motors 2000 hp andlarger.

2.4.11 Nameplates and Rotation Arrows

2.4.11.1 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 heaterterminal box stating CAUTION: SPACE HEATERS MAY BE ENERGIZED. Thenameplate shall be black engraving on a yellow background.


The Purchasers identification information, including project number, purchaseorder number and equipment number, shall be stamped on a separate nameplate.

3 ACCESSORIES

3.1 Terminal Boxes

3.1.1 Decision:

Oversized boxes to accommodate wire size and any other options specified onData Sheet (Motor /Generator) shall be provided.

3.1.6.a Decision:

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

3.1.6.b Decision:

If the terminal box contains accessories (e.g., current transformers, surgearresters, 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.
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SEP.020

PDVSA N278

Pgina 9


PDVSA

3.1.8 Decision:

Secondary leads shall be provided.


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 shallbe in rigid metallic conduit, with the exception that the final 0.6 m may be in flexconduit to facilitate connection to end devices.

3.2 Winding Temperature Detectors

3.2.1 Decision:

Winding temperature detectors shall be provided of the type specified on theDataSheet (Motor / Generator).

3.3 Bearing Temperature Detectors

3.3.1 Decision:

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

3.4 Space Heaters

3.4.1 Decision:

Space heaters shall be provided in the motor enclosure.


Space heaters shall be arranged so that heat is radiated from both sides to provideuniform heating of the stator windings. The heaters shall maintain the temperatureof the motor windings at approximately 5 C above the ambient temperature. The

surface temperature of the heater elements shall not be greater than 80 percentof the autoignition temperature, as specified on the Data Sheet (Motor /Generator), or 200 C, whichever is less.

3.5 Screens and Filters

3.5.4 Decision:

Filters shall be provided for WPII motors. Entire filter element and supportassembly shall be constructed of AISI 300 series stainless steel.
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PDVSA N278

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PDVSA


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

3.6 Alarms and Control Devices for Motor Protection


Alarms and control devices shall be equipped with singlepole, doublethrowswitches with minimum ratings of 10 Amps at 120 Volts AC and 3 Amps at 125Volts DC.

3.6.4.2 Add:

Each synchronous motor shall be equipped with a brushless excitation systemconsisting of a three phase alternating current (AC) exciter with revolvingarmature and stationary field, threephase bridge rectifier, motor field starting anddischarge resistor, and necessary static control modules to provide full functionexcitation control. The brushless excitation system shall be totally enclosedforcecooled utilizing air ducted from the main motor air stream.

Static control devices shall require no planned onsite adjustment for changes inambient conditions or repeated use of components. The control modules shallbe replaceable as complete components requiring no contingent modifications ofwiring or circuitry and no on site tuning or adjustment.

Rotating control modules and devices that are mounted on the shaft and rotorshall be readily accessible through easily removable covers or plates and shall notrequire extensive disassembly of the motor housing for removal.

The excitation system shall be provided with an automatic system to detectabnormalities, as specified on the Data Sheet.

4 INSPECTION, TESTING AND PREPARATION FORSHIPMENT

4.1 General

4.1.1 Decision:

The Vendor shall provide 10 working days advance notice to the Purchaser beforeeach inspection or test, except for the final test which requires 15 working daysadvance notice.

4.2 Inspection

4.2.1 General

4.2.1.1.a Decision:

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PDVSA

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. Magneticparticle and liquid penetrant inspection shall be performed on all shaft welds.

4.2.2 Material Inspection


When radiographic, ultrasonic, magnetic particle, or liquid penetrant inspection ofwelds or materials is required or specified, the tests are to be conducted per theapplicable sections of ASTM and ASME Standards.

4.2.2.2 Delete

4.2.2.3 Delete

4.2.2.4 Delete

4.2.2.5 Delete

4.2.3 Inspection

4.2.3.2 Decision:

For all machines having circulating pressure oil systems, the oil system furnishedshall meet the cleanliness requirements of API 614.

4.2.3.3 Decision:

The Purchaser may inspect for cleanliness the equipment and all piping andappurtenances 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 beingwithin the allowable values by testing of the parts, welds or zones.


The Vendor shall submit their quality program to the Purchaser for review.

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PDVSA N278

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PDVSA

4.2.3.6 Decision:

The tests listed in 4.2.3.6 shall be performed.

4.3 Final Testing

4.3.1 General


The Purchaser reserves the right to observe the manufacturing, testing,dismantling, inspection, and reassembly of the equipment.

4.3.2 Routine Test

4.3.2.d Decision:

The preferred values listed in Table 5 shall be used.

4.3.4 Stator Tests

4.3.4.1 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 rated6 kV and above in accordance with IEC 894. The acceptance criteria shall bemutually agreed upon between the Vendor and Purchaser.

4.3.4.4 Decision:

Water immersion or spray test shall be performed on all motor stators equippedwith sealed insulation systems.

4.3.5 Special Tests

4.3.5.1.1 Decision:

Complete test shall be performed on one motor of each group of identicallydesigned and manufactured motors.

4.3.5.1.2 Decision:

Bearing shall be disassembled and visually inspected per paragraph 4.3.2.1i, butdimensional checks are not required. There shall be no evidence of babbitt flowor smearing and no metal transfer between the shaft and bearing. Where thelubricant is accessible, its condition shall be visually examined after the run.

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PDVSA

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 andabove and when motors are applied with adjustable speed drives.

4.4 Preparation for Shipment

4.4.3.6 Decision:Shipping skid shall be provided.

5 GUARANTEE AND WARRANTYModify to read:

See other purchase documents for Guarantee and Warranty details.

6 VENDORS DATA

6.1 Proposal

6.1.4.a Decision:

The motors average torque versus speed during starting at rated voltage and at80 percent rated voltage shall be supplied.

6.1.4.b Decision:

The motors current versus speed during starting at rated voltage and at80 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 112method used during the test) shallbe supplied.

6.1.4.h Decision:

When the motor is driving a load having a variable torque during each revolutionof the motor shaft, the Vendor shall provide: the maximum current variation underactual operating conditions, the calculated motor efficiency under theseconditions based on an expected minimum efficiency, and the method ofcalculating the efficiency under operating conditions.

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6.1.16 Decision:

Vendor shall provide an outline of all necessary special weather and winterizingprotection required for the motor.

6.1.18 Decision:

Vendor shall provide rate schedules for an erection supervisor.

6.2 Contract Data

6.2.2 Drawing and Data Requirements


Vendor to provide one (1) reproducible set of drawings plus the specified numberof copies of all documentation and operating manuals as indicated on the DataSheet (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

B

For

Review

C

Final

Certified

D

As

Built

DESCRIPTION

(The following items are described in moredetail in API 541)

X X X Dimensioned outline drawings with majorand minor connections

X X X Foundation loading diagrams

X X Schematic wiring diagrams

X X X Flow diagrams

X X X Detail drawings and crosssectional dra-wings

X X X Erection/assembly drawings

X X Calculations torsional/lateral response

X X X Predicted performance curves

X X Vendors data reports

X Performance test reports

X(1) Installation, maintenance, and operatinginstructions

X Recommended spare parts list

A. Bidder shall furnish these documents with proposal.

B. Vendor shall furnish these documents for Purchasers review and shallreceive Purchasers authorization prior to proceeding with fabrication.

C. Vendor shall furnish these documents as part of the final certifieddocument submittal
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SEP.020

PDVSA N278

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PDVSA

6.2.3 Delete

6.2.4 Delete

6.2.5 Documentation Content (Add)

6.2.5.1 All engineering data provided for this equipment shall represent the actual

equipment specified and ordered.

6.2.5.2 Typical drawings are acceptable only if they are revised to specifically identify theequipment, accessories, wiring and dimensions being furnished.

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