THE ISRAEL ELECTRIC CORPORATION LTD. · PDF fileName Of Item / Project Full rewinding of...

THE ISRAEL ELECTRIC CORPORATION LTD.

GENERATION DIVISION

SPECIFICATION GD1/16

POWER STATION HIGH-VOLTAGE MOTOR REWINDING

INDUCED DRAFT FAN MOTOR RUTENBERG 3-4

Prepared by:

Checked by: Relu ILIE

Approved by: Igor GOBENKO

December 2016

6SPECIFICATION GD1/1 THE ISRAEL ELECTRIC CORPORATION LTD

GENERATION DIVISION

2

1. Purchaser

The Israel Electric Corporation Ltd. (IECo) - Israel.

2. Name Of Item / Project Full rewinding of induced draft fan motor Rutenberg 3-4.

3. Location Of Item / Project

The motor covered by this specification is located in Purchaser’s power station or

storage.

4. Scope The scope of work covered by this specification is full rewinding of induced draft

fan motor stator, located in Rutenberg 3-4 power station.

Based on results of tests from Item 11.1 and motor history, the scope of work shall

be in details defined between Purchaser and Contractor.

4.1. Project Description

N/A

4.2. Scope Of Supply The motor name plate rated data for the specific motor to be repaired are as

following. The single line diagram is attached to this specification. IECo will

decide if the motor to be repaired is originally made either by KONČAR

Croatia, respectively by ABB Switzerland as detailed below.

4.2.1. Phases: 3

4.2.2. Frequency: 50 Hz

4.2.3. Rated voltage: 13200 V

4.2.4. Rated speed: 746 rpm

4.2.5. Insulation Class: F

4.2.6. Rating: 6125 kW

4.2.7. Rated current: 314 A

4.2.8. Power factor: 0.88

4.2.9. Connection of stator winding: star

4.2.10. Original manufacturer: KONČAR Croatia, respectively ABB

Switzerland

4.2.11. Type: 6AJZ0a 900L1-8, respectively ONG 900 fa 8

4.2.12. Serial number: 23358, respectively HM 1005511

4.2.13. Protection: IP 55, respectively W24.

The scope of work shall include at least the following (but not only):

4.2.14. Stator core flux test (including thermographic test), after removing the

old coils and after installing the new coils.

4.2.15. Full rewinding, which shall include dedicated turn insulation (in

addition to strand insulation)

4.2.16. End-winding support hardware repair or replacement (if necessary)

4.2.17. Replacement of motor heaters


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4.2.18. Renovation or replacement of motor main terminals. It shall include

suitable protection for overvoltage originated by vacuum circuit

breakers (surge arresters and capacitors)

4.2.19. The neutral point of stator windings shall be externally accessible and

shall allow dismantling in order to permit each phase separate

insulation testing.

4.2.20. Replacement of support isolators

4.2.21. Cleaning and painting the motor and motor leads box (first layer

epoxy and second layer polyurethane RAL 1023).

4.2.22. Replacement of the bearings (IECo will supply the bearings)

4.2.23. Replacement of the RTD's

4.2.24. Rotor check and repair (if necessary)

4.2.25. Rotor balance, if repaired

4.2.26. Check, test and adjustment of accessories (e.g. cable entries, earthing

bolts, terminal boxes, terminal marking, enclosure, nameplate labels,

lubrication, fans, thermal monitors, coolers etc.).

5. Terminal Points &Terminal Connections N/A

6. Cyber & Information Security N/A

7. Quality Assurance & Quality Control

7.1. General Quality Requirements

To be checked by Purchaser's Quality Control representative.

The manufacturing and all components shall confirm to quality requirements

and shall ensure high reliability. The Bidder shall submit with his proposal

copies of quality assurance and quality control procedures. The Bidder shall

provide a full I&T plan with references to his shop specifications, standards

used, and acceptance criteria.

The acceptance tests (paragraph 11.2) shall be performed in the factory, in

presence of Purchaser’s Quality Control representative. The purchaser reserves

the right to send a representative to attend part or all of the acceptance tests.

The contractor shall include in its technical offer a test plan (appendix A),

which will include at least all of the tests according to this specification

(paragraph 11.2 - acceptance test), including tentative time schedule.

The contractor shall announce the updated time schedule, immediately after

receiving the order and shall update it if necessary.

The Contractor shall notify IECo by a non-conformance report in any case or

process a problem occurs, for any component which is out of specification, for

any component testing if a failure occurs.

7.2. Interchangeability


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The repaired motor shall provide the same or better parameters, characteristics

and performance, from all points of view, as the motor before repairing.

8. Standards & Codes In principle, the required tests procedure shall conform to IEC relevant standards

(mainly IEC 60034 series).

For tests not covered by IEC standards, ANSI, IEEE, NEMA, VDE standards shall

be applied, or the normal Purchaser internal practice.

9. Technical Documentation

9.1. General N/A

9.2. Technical Documentation Attached to Proposal

The Bidder shall supply to Purchaser the guarantee values of motor relevant

data that will be achieved after the repair.

The tolerances for guarantee values shall be according to IEC 60034-1.

9.3. Technical Documentation to Deliver after Award Notification The Contractor shall provide with the repaired or overhauled motor all data and

drawings showing the details of the work performed (i.e. active core

dimensions, slot details, insulation material type, cross section of coils, rated

power if changed, losses if influenced by repair, etc.).

If applicable, these data shall be presented comparatively with the condition

before repair.

In addition, the Contractor shall supply type and routine test reports and

operation and maintenance manual (if relevant).

10. Technical Requirements

10.1. Environmental Considerations & Service Conditions

• The altitude of the power station does not exceed 1000 m above the sea

level.

• The motor shall be outdoor mounted.

• The expected ambient air temperatures are:

- Maximum momentary................. .........................+45°C

- Minimum momentary.................. .........................-10°C

- Monthly average of the hottest month. .................+30°C

- Yearly average........................... .......... ..............+20°C

• The motor is expected to be exposed to long dry periods without rain,

sometimes with very fine sand dust, changing suddenly to periods of high

humidity and rain.

• The motor might also be exposed to a moderate combination of conductive

or abrasive dust (such as coal dust, fly ash, etc.), sulfur smokes ,moisture,

etc., as encountered in usual power plant applications.

• The motor at seashore location is expected to be additionally exposed to

coastal conditions with salt laden spray and storms.


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• The motor might be exposed during summer days to very intensive solar

radiation.

10.2. Reliability, Availability, Maintainability (RAM)

The repair performed shall be intended to improve the reliability and

availability of the motor.

10.3. Functional Requirements

10.3.1. The stator winding insulation shall be of Class F or Class H, but the

temperature rise shall correspond to Class B conditions.

10.3.2. The insulation system of stator winding shall be Vacuum Pressure

Impregnated (VPI). If approved by IECo, resin rich insulation system

can be used, assuring a similar winding quality, reliability and

operation life as VPI.

10.3.3. The Contractor shall use wires with at least the same cross section as

the existing one in the motor.

10.3.4. If applicable for repairing work, the rotor squirrel cage shall be made

of copper or copper-alloy bars.

10.3.5. The minimum monitoring devices (RTD's, thermocouples, etc.) shall

be of the same type and quantity as in the motor before the repair /

overhaul.

11. Tests & Inspections

11.1. Motor Test Before Repair

11.1.1. The motor shall be dismantled and tested in presence of Purchaser's

representative. The Contractor shall send to the Purchaser an initial

detail report of the condition of the motor.

11.1.2. At least the following tests shall be performed:

11.1.2.1. Visual inspection of stator and rotor.

11.1.2.2. Air gap clearance measurement.

11.1.2.3. Measurement of insulation resistance of stator winding, at 5000

V DC.

11.1.2.4. Measurement of stator winding resistance.

11.2. Acceptance Tests


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11.2.1. The Purchaser has the right to witness any process or tests performed

in the Contractor's facilities without any additional price. The

witnessing will be performed in such way to avoid any impact on the

contractual repair or overhaul schedule/delivery time.

11.2.2. The tests and acceptance conditions detailed in the items below shall

be completed. Additional tests and additional/changed acceptance

values can be agreed between Purchaser and Contractor.

11.2.3. Factory tests shall be performed for each coil before install, e.g.:

• Strand – strand isolation check

• Insulation resistance & PI

• DC Ramp

• Dissipation Factor and Tip-Up

• Partial Discharge

• Final Hi-Pot

These tests shall all have acceptance criteria spelled out in advance

and reports shall be supplied for each coil.

11.2.4. The following tests shall be performed on 2 sample coils:

• Voltage Endurance

• Surge test (IEC 60034-15)

• Hi-Pot to Breakdown

• Dissection

A full report on these tests shall be provided.

11.2.5. The following tests shall be performed on the repaired motor in the

factory, in presence of Purchaser’s representative:

11.2.5.1. Measurement of stator winding resistance, each phase

separately (the winding neutral point is accessible by 4.2.16).

For acceptance, each measurement shall not differ from each

other by more than 2%.

11.2.5.2. Measurement of stator insulation resistance and polarization

index, each phase separately (the winding neutral point is

accessible by 4.2.16), at 5000 V DC.

The minimum acceptance value of insulation resistance at 40°C

shall be 300 MΩ.

The minimum acceptance value of polarization index shall be

2.0.

11.2.5.3. Measurement of insulation resistance of heaters, thermometers,

thermocouples, thermistors, thermostats, etc. used for windings,

bearings or cooling circuits at 500V DC, 1 min.

11.2.5.4. Measurement of no-load current (including current symmetry)

and losses at rated voltage and frequency.


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The no-load running shall be performed for about 1÷3 hours,

until thermal equilibrium is achieved.

The no-load currents unbalance shall not exceed 20%.

11.2.5.5. Check of direction of rotation versus phase sequence and mark

it on the wires and the motor. The phase sequence in the

connection box shall be kept as it was before starting the work.

11.2.5.6. Measurement of mechanical vibrations for housing and

attachments, performance of noise assessment. Maximum

acceptable values according to ISO 10816-3: r.m.s. velocity 2.3

mm/s, radial and axial direction, at bearing housing.

11.2.5.7. Behavior of bearings (lubricant level, temperature, noise,

vibrations).

11.2.5.8. On motors supplied with insulation bearings, measurement of

bearing insulation resistance at 500V DC, 1 min. and

measurement of shaft voltage.

11.2.5.9. Measurement of locked-rotor torque and current (including

current symmetry) at rated current times service factor, rated

frequency and reduced voltage. The short-circuit currents

unbalance shall not exceed 5%.

11.2.5.10. Performing of moisture withstand test for sealed stator winding

(water immersion or spray test) according to NEMA MG1. The

Contractor shall announce to the purchaser at which method he

will perform the test (either submerge or spraying), in the

technical stage.

11.2.5.11. Measurement of dielectric dissipation factor (tgδ) with different

applied voltages, up to rated voltage, each phase separately.

The maximum acceptance value of tgδ shall be 2% (at 20°C÷

30°C). The maximum acceptance change in tgδ value from

20% of rated voltage to rated voltage shall be 50%.

11.2.5.12. Partial discharge measurements of stator with voltages up to

rated voltage, each phase separately.

11.2.5.13. Power frequency withstand test of the stator winding with

voltage (2UN + 1) kV for 1 min, each phase separately.

11.2.5.14. Impulse withstand test of main insulation of 2 individual

sample coils with peak voltage of 4UN + 5 kV (1.2/50µs).


GENERATION DIVISION

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11.2.5.15. Impulse test (inter-turn insulation) withstand test of 2 sample

coils with peak voltage of 0.65 x (4UN + 5) kV having a front

time of 0.2 µs.

11.2.5.16. Air gap clearance measurement. As acceptance condition, the

difference between the measurements at diametrical opposite

air gap points shall be less than 5% from air gap average

clearance.

11.2.5.17. Rotor tests – analyses of stator current harmonics by Motor

Monitoring or similar method (if applicable for repairing

work).

11.2.5.18. Over-speed test for rotor if repaired, at 120% rated speed. In

addition, rotor dynamic balancing test, if repaired.

11.2.5.19. Check, test and adjustment of accessories (e.g. cable entries,

earthing bolts, terminal boxes, terminal marking, enclosure,

nameplate labels, lubrication, fans, thermal monitors, coolers

etc.).

11.2.5.20. Direct rated voltage starting test, including measurement of

starting currents and starting time and successive starts test

according to motor design.

This test can be performed also in Contractor or Purchaser’s

facilities under Contractor responsibility. Acceptable locked

rotor current is until +20% of rated value.

11.3. Field Tests

11.3.1. The Purchaser shall have the right to perform all or a part of the

following field tests, on motor mounted in power station, before the

first operation following the repair:

11.3.1.1. Check of direction of rotation versus phase sequence.

11.3.1.2. Measurement of no-load current and losses (with the load

uncoupled).

11.3.1.3. Measurement of mechanical vibration.

11.3.1.4. Measurement of insulation resistance and polarization index at

the same DC voltage as in Items 11.2.5.2, 11.2.5.3.

11.3.1.5. Measurement of partial discharge with voltage up to nominal

voltage.


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11.3.1.6. Power frequency withstand test of stator winding at 0.80 x (2UN

+1) kV

11.3.1.7. Tgδ measurement according to item 11.2.5.11.

11.3.1.8. Measurement of bearing insulation resistance on motors

supplied with insulated bearings.

11.3.1.9. Rotor tests – analyses of stator current harmonics by Motor

Monitoring according to item 11.2.5.177.

11.3.1.10. Check of the accessories.

11.3.1.11. Direct rated voltage starting test, including measurement of

starting currents and starting time according to item 11.2.5.20.

12. Packaging & Delivery

12.1. The repair or overhaul shall be performed in Contractor’s factory.

The transportation to and from the Contractor’s factory, including the

insurance, shall be the Contractor’s responsibility (as an integral part of the

contractual repair or overhaul schedule/delivery time) unless otherwise agree.

13. Storage & Handling The Contractor shall submit instructions for long term motor storage.

14. Nameplate & Marking

The contractor shall renew the nameplate, include IECo motor number.

The contractor shall mark the motor phases.

15. Notes

Within this specification, the word "shall" indicates mandatory requirements, from

which no deviation is permitted. The word "should" indicates a preferred or

recommended possibility.

IECo keeps its rights to qualify or disqualify any Bidder following the fulfilling of

any specification requirement.

All deviations from this specification shall be separately listed. In the absence of

such list, it will be presumed that the provision of the specification are complied with

by the Bidder.

(See also non-conformance reporting requirement in item 7.1 above).

16. Special Requirements

16.1. Warranty The warranty period of the repaired motor shall be at least 12 months from first

operation.

16.2. Repair Duration


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The works detailed above (scope of work and tests) shall be performed in the

Contractor facilities during 60 calendar days or less.

16.3. Threshold Conditions 16.3.1. The Contractor shall provide with the proposal a reference list

showing his proven experience performing rewinding of similar

motors (rated power, voltage) - at least 2 similar motors in the last

five years.

16.3.2. The Bidder shall include in his technical proposal ISO-9001

qualification certificate or similar.

16.4. Others 16.4.1. The repair or overhaul shall be performed in Contractor’s factory.

16.4.2. The Contractor shall issue a Root Cause Analysis of the original failed

motor.

16.4.3. The Contractor shall issue an acceptance test report, before shipment.

16.4.4. The Contractor shall issue a final report, within 30 days after

completion of the scope of work.

16.4.5. All documentation shall be issued in English or Hebrew.


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Appendix A

TEST PLAN

CONTRACTOR`S: NAME, I&T PLAN TITLE, THE PRODUCT INSPECTED/TESTED,

AND DOCUMENT IDENTITY & APPROVAL.

PURCHASER`S : NAME AND PROJECT`S NAME AND LOCATION

REMARKS

TIME SCHEDULE

INSPECTED/TESTED BY :

WP/HP OR

OTHER

APPLICABLE

DOCUMENTS

THE INSPECTI

ON OR TEST

NO.

OTHER PURCH-

ASER CONTR- ACTOR

SUB-CONT./

SUPPLYER


GENERATION DIVISION

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