GIS 12 205 17 November 2003

Guidance on Industry Standard for Synchronous Motors (IEC) GIS 12-205 BP GROUP ENGINEERING TECHNICAL PRACTICES Document No. GIS 12-205 Applicability Group Date 17 November 2003 17 November 2003 GIS 12-205 Guidance on Industry Standard for Synchronous Motors (IEC) Downloaded Date: 6/17/2008 10:15:08 PM The latest update of this document is located in the BP ETP and Projects Library Page 2 of 16 Foreword This is the first issue of Engineering Technical Practice (ETP) GIS 12-205. This Guidance on Industry Standard (GIS) is based on the following heritage documents from merged BP companies: AMOCO (ACES) A EL-MT-546-P Electrical—Motors—Synchronous—Supply Specification ARCO (APCES) ES 406-91 Form-Wound Brushless Synchronous Motors 500 Horsepower and Larger BP (RPSE) RP 12-11 Electrical Systems and Installations - Motors GS 112-4 Guidance for Specification High Voltage Induction Motors BP Chemical US CP 17-3-3 Synchronous Motors Copyright 2003, BP Group. All rights reserved. The information contained in this document is subject to the terms and conditions of the agreement or contract under which the document was supplied to the recipient’s organization. None of the information contained in this document shall be disclosed outside the recipient’s own organization without the prior written permission of Manager, Standards, BP Group, unless the terms of such agreement or contract expressly allow. 17 November 2003 GIS 12-205 Guidance on Industry Standard for Synchronous Motors (IEC) Downloaded Date: 6/17/2008 10:15:08 PM The latest update of this document is located in the BP ETP and Projects Library Page 3 of 16 Table of Contents Page Foreword 2 1. Scope 5 2. Normative references. 5 3. General 5 3.1. Documentation 5 3.2. Exceptions 5 3.3. Conflicts 6 3.4. Quality assurance . 6 4. Standard design requirements. 6 4.1. General. 6 4.2. Certification for use in hazardous areas 7 5. Special design requirements 7 5.1. Duty and rating . 7 5.2. Construction 7 5.3. Environmental protection 7 5.4. Windings and cable terminations 8 5.5. Bearings and lubrication 10 5.6. Critical speeds 11 5.7. Vibration . 11 5.8. Plant identification. 12 5.9. Mechanical handling . 12 5.10. Painting. 12 6. Noise . 12 6.1. Noise emission . 12 6.2. Noise reduction. 12 7. Tests 13 7.1. Standard tests. 13 7.2. Overspeed test . 14 7.3. Heat run 14 7.4. Vibration . 14 8. Documentation. 14 8.1. Data sheet 14 8.2. Coil quality and interturn tests. 14 8.3. Winding data. 14 8.4. Test documentation 14 8.5. General arrangement drawing. 14 Bibliography 15 17 November 2003 GIS 12-205 Guidance on Industry Standard for Synchronous Motors (IEC) Downloaded Date: 6/17/2008 10:15:08 PM The latest update of this document is located in the BP ETP and Projects Library Page 4 of 16 17 November 2003 GIS 12-205 Guidance on Industry Standard for Synchronous Motors (IEC) Downloaded Date: 6/17/2008 10:15:08 PM The latest update of this document is located in the BP ETP and Projects Library Page 5 of 16 1. Scope This GIS provides guidance on industry standard for the design, materials, fabrication, inspection, testing, documentation, and preparation for shipment of synchronous motors based on IEC standards. 2. Normative references The following normative documents contain requirements that, through reference in this text, constitute requirements of this technical practice. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply. However, parties to agreements based on this technical practice are encouraged to investigate the possibility of applying the most recent editions of the normative documents indicated below. For undated references, the latest edition of the normative document referred to applies. International Electrotechnical Commission (IEC) IEC 60034-1 Rotating electrical machines – Part 1: Rating and performance. IEC 60034-5 Rotating electrical machines – Part 5: Degrees of protection provided by the integral design enclosures of rotating electrical machines (IP code) – Classification. IEC 60034-6 Rotating electrical machines – Part 6: Methods of cooling (IC code). IEC 60034-7 Rotating electrical machines – Part 7: Classification of types of construction, mounting arrangements and terminal box position (IM Code). IEC 60034-14 Rotating electrical machines – Part 14: Mechanical vibration of certain machines with shaft heaths 56 mm and higher – Measurement, evaluation and limits of vibration. IEC 60079 Electrical apparatus for explosive gas atmospheres – All Parts. International Standards Organization (ISO) ISO 281 Rolling bearings – Dynamic load ratings and rating life. ISO 492 Rolling bearings—Radial bearings—Tolerances. ISO 1940-1 Mechanical vibration—Balance quality requirements of rigid rotors—Part 1: Determination of permissible residual unbalance. 3. General 3.1. Documentation A specification suitable for enquiry or purchasing can be derived from this section of the GIS by retaining the technical body unaltered but omitting the data page and all commentary. This section of the GIS shall be read in conjunction with an enquiry or purchase order and all data sheets associated therewith. The purchaser and vendor shall both complete the data sheets. 3.2. Exceptions Tenders for the supply of equipment against this section of the GIS shall either include an unqualified affirmation regarding compliance with this section of the GIS or a complete list of exceptions. 17 November 2003 GIS 12-205 Guidance on Industry Standard for Synchronous Motors (IEC) Downloaded Date: 6/17/2008 10:15:08 PM The latest update of this document is located in the BP ETP and Projects Library Page 6 of 16 A vendor may offer other suitable proposals where price or technical advantage may accrue, but such proposals shall form a supplement to the main tender. 3.3. Conflicts If any of the reference documents conflict and the provisions of this GIS do not establish definition, then the vendor shall highlight this, and shall state the basis of design used. 3.4. Quality assurance Verification of the vendor s quality system is normally part of the pre-qualification procedure, and is therefore not specified in the core text of this section of the GIS. If this is not the case, clauses should be inserted to require the vendor to operate and be prepared to demonstrate the quality system to the purchaser. The quality system should ensure that the technical and QA requirements specified in the enquiry and purchase documents are applied to all materials, equipment and services provided by sub-contractors and to any free issue materials. 4. Standard design requirements 4.1. General Motors shall comply with relevant parts of IEC 60034. Any requirement to meet other national interpretations of IEC 60034, with or without CENELEC Harmonisation Document requirements, must be identified and agreed in writing between the purchaser and the vendor. This procedure is intended to be the means by which particular local needs can be met whilst at the same time properly documenting deviations from the normal BP requirements. The following requirements are considered to be ‘normal’ unless site specific conditions call for other, more stringent, requirements that shall be specified on the data sheet: Motors shall be capable of providing the momentary excess torque as specified in IEC 60034-1. Synchronous machines are not suitable for reconnecting to a supply just after being switched off or if synchronism is lost. To avoid this condition suitable controls and protection should be provided. This could be provided as part of the switchgear supply where generator protection is included in that package but it is not uncommon for this to form part of a generator control package where that package includes the generator protection. The motor torque characteristics during run up shall be adequate for starting the driven load under the applied voltage, and load torque and inertia conditions specified. The motor shall be suitable for a maximum of 1000 starts per year. The motor shall be capable of the following starting performance with the conditions specified: Two starts in succession, coasting to rest between starts, with the motor initially at ambient temperature One start with the motor initially at its rated load operating temperature The manufacturer shall assign safe stalled times for cold and hot conditions. These are the times that the motor may remain stalled without damage. The cooling arrangement shall be IC511 for air-cooled machines and IC71W for water-cooled machines. Cooling arrangement shall be in accordance with IEC 60034-6. Cooling water for water-cooled motors shall normally have a maximum temperature of 25oC unless higher temperatures are specified in the data sheet. Cooler materials shall ultimately be matched to the cooling water analysis (furnished to the successful 17 November 2003 GIS 12-205 Guidance on Industry Standard for Synchronous Motors (IEC) Downloaded Date: 6/17/2008 10:15:08 PM The latest update of this document is located in the BP ETP and Projects Library Page 7 of 16 bidder) and the proposed materials shall be identified. Provision should be made within the motor to prevent leakage of cooling water on to the windings or rotating parts of the motor. Air-cooled motors shall not draw their air from the drive end of the machine and should be designed for the maximum average ambient temperature specified in the data sheet. If electrically operated fans are employed these shall have full redundancy and bidders shall clearly state the output achievable with a single fan operating. All motors for use in hazardous areas shall comply with the relevant parts of IEC 60079 or alternatively the relevant parts of the CENELEC 500XX series of documents or national variants. Motors for use in hazardous areas in the European Economic Area must comply with the relevant EN 500XX series CENELEC standards or national variants and these should be referenced in place of the IEC 60079 series for the relevant protection concepts. Horizontally mounted machines shall be IM 1001 and vertical flange mounted machines shall be IM 3011 in accordance with Code II of IEC 60034-7. Component parts of the motor shall be bonded together and to the earth terminal in order to prevent arcing and sparking in service. All components of the excitation circuit shall be sized to continuously satisfy the maximum flux demand of the synchronous motor. 4.2. Certification for use in hazardous areas Motors for use in Zone 1 or Zone 2 Hazardous Areas shall have certification from a recognised National Certifying Authority. The manufacturer shall submit copies of the relevant certification documents with the tender. 5. Special design requirements 5.1. Duty and rating Motors shall have a continuous running duty designated as type S1 in accordance with paragraph 4.2.1 of IEC 60034-1. Motors shall be capable of meeting their specified duty for 26,000 hours (3 years) without being stopped for maintenance purposes. 5.2. Construction The motor frame and enclosure shall be of welded steel plate and sheet to form a rigid, self-supporting and torsion-resistant assembly that can be shipped in one piece. The base structure shall have adequate facilities for lifting, levelling, aligning and anchoring the entire motor. The preferred configuration of the motor and brushless exciter shall be of horizontal construction with two or three pedestal-type sleeve bearings on a common base plate, allowing the separate removal of the main motor and exciter. 5.3. Environmental protection The degree of ingress protection shall be in accordance with IEC 60529 and suitable for the application and installation site. Where no data is available to indicate a more stringent specification and where an outdoor installation is involved, the protection shall be IP55. The degree of ingress protection required (IP55) is entirely suitable for situations where machines are not subject to excessive dust settlement or immersion in water. 17 November 2003 GIS 12-205 Guidance on Industry Standard for Synchronous Motors (IEC) Downloaded Date: 6/17/2008 10:15:08 PM The latest update of this document is located in the BP ETP and Projects Library Page 8 of 16 If any doubt exists then the particular conditions pertaining should be evaluated and a special enclosure agreed between purchaser and vendor. Where the machine will be installed inside an enclosure a rating of IP20 may be contemplated. However where the enclosure is large and there could be moisture or dust/debris above the machine the minimum protection to be specified should be IP23 Machines shall be suitable for a Relative Humidity of 90% with occasional condensation. Vertically mounted motors having a single shaft extension at the bottom shall be protected with a rain cowl (IPX2) supplied by the manufacturer. Anti-condensation heaters shall not be provided unless specified on the data sheet. If heaters are provided, they shall be easily accessible without requiring dismantling of the motor. The purpose of an anti-condensation heater is to preclude the possibility that the specified insulation level of the machine is seriously reduced by the entry of water or water vapour into the machine. Modern non-hygroscopic insulation materials largely obviate the possibility of this occurring and manufacturers generally take good care to ensure that all conducting items are insulated to a high standard. In order to prevent the ingress of water or other harmful matter prior to cabling, open cable entries shall be adequately sealed (IP55) before the motor is despatched from the manufacturer s works. Where a drain hole is provided, it shall be at the lowest point on the stator, subject to accessibility for the removal of the threaded plug when the machine is mounted in the service position. In the case of motors for use in hazardous areas, the drain hole shall be sealed with a draining device approved by the Certifying Authority. Care must be exercised to ensure that the means of removing and replacing drain plugs are not impeded by the position in which the motor is mounted. This is not always the responsibility of the motor manufacturer but often the responsibility of a package (e.g. pump set) vendor who provides the mounting (e.g. bedplate) for the motor. 5.4. Windings and cable terminations Stator and rotor windings of the motor and exciter shall generally be constructed using Class F insulation materials. During normal service, the temperature rise values of Class B materials shall not be exceeded. The temperature rises shall be limited to Class B unless the manufacturer offers Class H insulation of proven design in which case the temperature rise to Class F shall be considered. The required rating of a motor for a particular piece of driven equipment is usually defined by the supplier of the driven equipment, after taking into account any BP requirements. This rating takes account of any design uncer