6131-A - Induction Motors 150KW and Larger
6131-A - Induction Motors 150KW and Larger
6131-A - Induction Motors 150KW and Larger
GENERAL SPECIFICATIONS
TABLE OF CONTENTS
1.0 SCOPE
3.0 GENERAL
3.1 APPROVAL
3.2 DEFINITIONS
4.0 DESIGN
4.1 GENERAL
5.1 ASSEMBLY
5.2 BEARINGS AND LUBRICATION
5.3 INSULATION SYSTEMS
5.4 MAGNETIC CIRCUIT
5.5 TERMINAL BOXES
5.6 GROUNDING
5.7 MARKING
5.8 FINISH
5.9 ACCESSORIES
6.1 TESTS
6.2 QUALITY ASSURANCE
GENERAL SPECIFICATIONS
1.0 SCOPE
This specification covers the basic requirements for AC induction motors over 150
kW , having form-wound windings for general purpose applications and for use in
hazardous locations.
2.1 Vendor shall meet or exceed the requirements of the latest edition of the following
codes, regulations and standards, except as superseded herein. In cases where
more than one code, regulation or standard apply to the same condition, the most
stringent shall be followed. In the event of a conflict between this specification and
other specifications or correspondence, the OWNER shall be consulted and a
ruling, in writing, shall be obtained before any work is started.
• IEC 72A Dimensions and output ratings - frame number 355 to 1000
• ISO R 281 Roller bearings - dynamic load ratings and rating life
2.3 Any deviation from this specification must be approved, in writing, by OWNER.
Such written approval must be obtained prior to the commencement of any work
which would constitute such a deviation.
GENERAL SPECIFICATIONS
3.0 GENERAL
3.1 Approvals
Site conditions, specific design data and accessories are specified on the Large
Electric Motor Data Sheet in Appendix A.
3.2 Definitions
An Observe Test or Inspection shall mean a test or inspection for which the
OWNER shall be notified of the time; however, the test will go on whether the
OWNER is present or not. An observed test will not necessarily be preceded by
preliminary tests without the OWNER.
OWNER shall mean the OWNER as set out in the Request for Quotation (RFQ) or
any other person, firm or corporation engaged by OWNER, to perform services to
which this specification is applicable.
Vendor shall mean the person(s) or company(ies) selling the product specified in
this Specification to the OWNER.
A Witness Test or Inspection shall mean a test or inspection that is carried out
with the OWNER present, and a hold applied to the production until the test or
inspection is carried out. A witness test shall be preceded by preliminary tests
without the OWNER.
4.0 DESIGN
4.1 General
4.1.1 As a minimum, motors shall be designed and constructed in accordance with the
requirements of IEC34.
4.1.2 Efficiency shall be evaluated on the basis that a reduction in operating losses will
support an additional capital cost. An "efficiency cost factor" is an amount
representing the additional capital cost that can be supported by a reduction in
operating losses of one kilowatt. This factor shall be provided on the Data Sheet.
GENERAL SPECIFICATIONS
Efficiency shall be. The Vendor shall state on the Data Sheet which method will be
used, and the stray load loss allowance. Manufacturer's guaranteed efficiency
value shall be used for this evaluation (see sub-section 6.1.2).
Motors tested that do not meet the quoted guaranteed efficiency value shall be
subject to a price reduction penalty. The penalty shall be calculated by multiplying
the efficiency cost factor (in dollars per kilowatt of losses) by the operating losses
(in kilowatts) that are in excess of the quoted value.
4.1.3 The motor Vendor shall provide means to facilitate rotor removal and state the
method on the Data Sheet.
4.1.4 The rotor assembly shall be dynamically balanced. For shafts with keyways,
balance with ½ key in the keyway. For shafts with large couplings such as damper
couplings, balance with ½ coupling weight. The use of solder or similar deposits is
not acceptable. Balance weights shall be securely fastened.
The removal of parent metal to achieve balance shall be done in such a manner as
not to affect the structural strength of the rotor.
The balance tolerance shall allow operation within the vibration limit specified. The
maximum allowable residual unbalance shall be determined from the following
equation:
Following the dynamic balance of the rotor, the calibration of the balance machine
shall be checked as described in IEC 34.
Provision for onsite balancing, without major disassembly, shall be provided for
motors greater than 500 kW.
Vendor shall notify the OWNER at least two (2) weeks prior to rotor balancing so
that at OWNER's option, arrangements can be made to observe these tests.
4.1.4 Locked-rotor current shall be kept as low as possible, and the maximum locked-
rotor current shall be 600% of the full load current.
4.1.5 The complete motor assembly shall have the motor first critical speed at a
minimum of 20% from the rated speed and no critical speed shall be within 10% of
twice the rated speed. Compliance shall be attested by having no significant
vibration during slow rundown greater than the vibration limits described above.
The motor manufacturer shall inform the OWNER of the motor critical speeds(s).
GENERAL SPECIFICATIONS
4.1.6 The motor shall be capable of an out-of-phase re-closing with the specified loads
with a volts per Hertz on re-application of voltage of 1.33 per unit, based on the
motors nameplate and frequency.
4.1.7 Motors shall have the starting capabilities listed in IEC 34. The Vendor shall inform
OWNER of any financial impact of the increased start capacity.
4.1.8 The Vendor shall state in his proposal the time for the stopped motor to cool down
after the maximum number of starts as per IEC 34 to allow one restart, without
supplementary ventilation.
5.0 FABRICATION
5.1.1 Motors shall be supplied complete with provision for lifting devices such as lifting
eyes and jack screws. If sole plates are supplied then provision for horizontal
jacking shall be provided.
The Vendor shall state on the Data Sheet, the maximum kilowatt rating that can be
installed in the frame size quoted.
5.1.2 Totally enclosed motors shall be equipped with stainless steel drains and plugs
located at the lowest point in the enclosure. Motors located outdoors shall have an
approved drain fitting installed in the bottom of the motor junction box.
5.1.3 Rotor construction for squirrel-cage induction motors shall have fabricated
aluminium copper or alloy bars. When fabricated copper rotor construction is
used, rotor bars shall be brazed with a phosphorus-free bracing material. After
fabrication, the entire rotor shall be coated with a suitable epoxy finish for the
prevention of corrosion from corrosive gases.
5.1.4 Where motors are provided with sleeve bearings and limited end-play couplings,
minimum motor rotor end-play and maximum coupling end-play limits shall be
followed as stated in IEC 34. Minimum motor rotor end-play shall be indicated on
the motor outline drawing.
GENERAL SPECIFICATIONS
5.2.1 For horizontal motors rated 370 kW and below, 1500 rpm or less, bearings may be
anti-friction or sleeve type. For horizontal motors rated above 370 kW, bearings
shall be sleeve type. For all motors with a synchronous speed rating of 3000 rpm,
bearings shall be sleeve type. Motors intended for belt-drive service shall be
equipped with anti-friction bearings.
5.2.3 Motors shall have one Drive-End (DE) bearing and one Opposite-Drive-End (ODE)
bearing unless otherwise approved by OWNER.
5.2.3 Anti-friction bearings shall have a rated L10 life expectancy of 50,000 hours
minimum for directly connected motors. The lifetime shall be calculated in
accordance with ISO R 281.
5.2.5 Sleeve bearings shall be of an oil lubricated, split-capsule type and have split
bearing brackets. The design shall permit bearing replacement without removing
the bottom bearing bracket.
5.2.7 Both bearings shall be insulated when the end-to-end shaft voltage exceeds 150
mV for anti-friction bearings and 200 mV for sleeve bearings. The DE bearing shall
be provided with a removable grounding device to bypass the insulation. The
motor manufacturer shall provide a nameplate mounted on the enclosure to
indicate the precautions necessary to maintain the insulation integrity. The
nameplate shall be in an easily visible location.
5.2.8 Grease lubricated bearings shall have a pressure grease fitting, and a drain fitting
located 180° from the grease fitting.
5.2.9 Seals shall be provided to prevent loss of grease and entrance of water, dust and
other foreign material into the bearing housing.
5.2.11 An inspection window shall be provided on all sleeve bearing motors to allow direct
observation of the oil ring(s).
5.2.12 Oil lubricated bearing housings shall have the following features:
• Oil reservoirs fitted with constant level oilers (Trico or equivalent) on non force-
lubricated bearings.
GENERAL SPECIFICATIONS
• Cleanable or replaceable oil level indicator marked with acceptable high and
low level limits. (The indicator shall be designed such that oil will not get
trapped in it, as this could give a false reading).
• Fill and drain openings (Drain opening shall be at the lowest point in the
reservoir).
5.3.1 Motors shall be furnished with a form-wound, Class F insulation system with
sealed windings, and be rated for Class B temperature rise.
5.3.2 The insulation system shall be post-winding Vacuum Pressure Impregnated (VPI)
with epoxy or polyester. The vacuum, pressure and time of impregnation shall be
such as to provide complete impregnation of the insulation.
The Vendor shall state what methods are used to verify complete impregnation,
such as capacitance measurement, impregnating an extra coil in dummy slots, etc.
5.3.3 Special attention shall be given to prevent conductor movement in the end turns by
bracing the coils.
5.3.4 The components of the insulation system shall be non-hygroscopic and compatible
with the physical (i.e. thermal, flexure, expansion) characteristics of the coils, stator
iron, support components and with each other.
Special attention shall be given to the voltage capability of the coils. The Vendor
shall provide motors with sufficient insulation such that the motors operate reliably
for the expected life (at least 25 years) on the OWNER's power and control
systems. This power system may include the use of vacuum contactors and
power factor correction capacitors as well as Adjustable Frequency Drives with
"Displaced Neutrals", or repeated fast rise time impulses. The OWNER will
provide the Vendor with details of the power system to be used upon request.
The magnet wire shall be enamel coated and wrapped with Dacron or mica tape,
unless it can be demonstrated that another proposed system is equivalent.
The turn insulation shall be such that when an unimpregnated coil is inserted into
the core, it shall be capable of withstanding from lead-to-lead a test voltage of 70%
of the values shown in IEC 85.
GENERAL SPECIFICATIONS
• Turn insulation.
• Ground wall insulation.
• Impregnation materials.
• Pressure, vacuum, temperature and cycle times.
5.4.1 The steel laminations shall be essentially free from burrs and shall be stacked in
such a way as to prevent uneven build-up of the core and irregular slots.
5.4.2. The inter-laminar insulation and the steel shall be capable of withstanding
temperatures of 400°C without detriment to their electrical and magnetic qualities.
5.4.3 The air gap shall be consistent and the maximum deviation from the average shall
not be more than 10% of the average air gap.
• Accommodate the number and size of wires as stated on the Data Sheet.
• Have a rigid insulated copper bus (or pad) and provision for terminating the
incoming line leads on the bus.
5.5.3 All terminal boxes shall be suitable for the area classification as stated in the Data
Sheet.
GENERAL SPECIFICATIONS
5.5.4 Auxiliary terminal strips shall be "Wiedmuller Type SAK" or approved equal.
5.5.5 The terminal box for power connections shall be designed to receive cable from
any of four directions.
5.6 Grounding
• One shall be installed on a part of the motor frame not normally disassembled
during operation or service, near its base.
• The other shall be installed inside the motor power terminal box.
5.6.2 Where surge capacitors or surge arrestors are installed inside the power terminal
box, they shall be grounded to the grounding stud, connector or busbar inside the
terminal box. In this case, a bonding jumper shall be installed between the
grounding stud inside the terminal box to the grounding stud on the motor frame,
for direct connection to an external grounding grid (i.e. ground rod). Grounding
conductors shall be kept as short as possible.
5.7 Markings
5.7.1 Motor nameplates shall be Type 304 stainless steel attached with stainless steel
pins and stamped with the applicable information required as per IEC 34.
5.7.2 For sleeve bearing motors, a permanent, durable indicator shall be provided to
show the rotor mechanical end-play limits. The indication method shall be
adjacent to a shaft shoulder, showing the allowable excursion of the shoulder.
5.7.3 Motor shafts or the end-play marker shall be marked to indicate the magnetic
centre.
5.8 Finish
5.8 Surfaces shall be clean, free of rust and degreased before paint is applied.
5.8.2 All metal surfaces required to be painted shall be given two (2) coats of rust
inhibiting primer.
5.8.3 At least one top coat of finish enamel shall be applied using the Vendor's standard
colour.
5.9 Accessories
GENERAL SPECIFICATIONS
5.9.1 Motor accessories shall be supplied as follows and as stated on the Data Sheet.
5.9.2 Motor windings shall contain the following Resistance Temperature Detectors
(RTDs) of the 100 ohm platinum type located in the stator slots.
Below 370 kW 1
370 kW and Above 2
5.9.3 For motors rated 370 kW and larger, each bearing shall be fitted with one
insulated, spring-loaded RTD of the 100 ohm platinum type inserted in the bottom
bearing shell.
5.9.4 When specified on the Data Sheet, surge arresting device(s) - lightning arrestor
and surge capacitor located in a power connection box when analysis predicts
excessive surge levels at the motor, shall be provided.
5.9.5 Space heaters shall be provided for motors located outdoors or other motors that
are likely to be subjected to a damp environment for extended periods of time with
the motor shut down. When the motor is located in a hazardous area, or
purge/pressurised to meet that classification, the space heater shall be of the
explosion-proof type. Space heaters shall be wired to a separate junction box, and
voltages are to be used as stated on the Data Sheet.
5.9.6 Vibration detection shall receive specific design requirements which may include
provision for mounting the probes and providing seismic or proximity type probes.
6.1 Tests
6.1.1 Each induction motor shall be given a routine (commercial) test per IEC 34 but with
vibration limits as per relevant section of this document, demonstrating freedom
from defects.
6.1.2 Unless otherwise specified, motors shall be given the following tests in addition to
those in IEC 34. Where a number of identical induction motors are supplied, and
when approved by OWNER, testing shall be done on one motor only.
GENERAL SPECIFICATIONS
• Full load heat run (dynamometer or back-to-back motor run test). Hot spot
RTD measurement shall be used to determine temperature rise in accordance
with IEC 34. The shim thickness required to compensate for thermal growth
shall be recorded on the test report.
• Sound level measurements and octave band analysis as per EEMUA 140.
• On 2 pole motors rated over 500 kW and 4 pole motors rated over 2000 kW, a
coast down test from 120% rated speed while securely mounted to a “massive
base” as specified in IEC 34-14. With 4 times the allowable unbalance
attached to the motor at each end, vibration shall not exceed 1.5 times the
levels quoted in IEC 34-14 at any speed within 10% of the operating range of
the motor.
• Breakdown torque.
6.1.3 Maximum temperature rise under rated load conditions shall not exceed the limits
for Class B insulation systems, as described in IEC 34. The method of
temperature measurement shall be by embedded detector (RTD) with the highest
value used as the acceptable criterion.
6.1.4 Vibration limits at no load and when load tested at full load with the temperature
stabilised at rated voltage and frequency shall not exceed those listed and
measured according to IEC 34. Vibration limits shall not be exceeded after
bearing temperatures and vibration levels have stabilised.
GENERAL SPECIFICATIONS
6.2.1 With its proposal, the Vendor shall state the Quality Assurance Standard (e.g. ISO
9001) to which the manufacturing plant has been certified. In addition, Vendor will
be required to demonstrate compliance through the Quality Control Audit by
OWNER.
6.2.2 The OWNER shall have unrestricted access to the Vendor's shop, shop
procedures, schedules, testing and inspection procedures and documents.
6.2.3 If requested, the Vendor shall make the motor designer available for design
requirements and review meeting.
6.2.4 Vendor shall make the plant's Quality Assurance Manual available for OWNER
review.
6.2.6 The OWNER shall be given a minimum of seven (7) days notice before shipment
so that a final inspection can be organised, if desired.
7.1 The Vendor shall submit the packing specifications and shipping methods to the
OWNER for approval.
7.2 Motors shall have the rotor shaft mechanically locked or supported to prevent
bearing damage in transit.
8.1 The Vendor shall supply a minimum of one reproducible copy of all drawings and
data unless otherwise specified on the Purchase Order.
8.2 For each motor, or if specified each motor rating, the following drawings and data
are required for proposal, drawing approval and certified (final) drawing stage (after
manufacturing):
GENERAL SPECIFICATIONS
Control Schematics X X
Wiring Diagrams X X
Bills of Material X X
Nameplate Data X X
Installation/Operation/Maintenance Data X X
8.3 The certified dimensional drawings shall show at least the following:
• Flanges - the ANSI rating, facing, bolt hole size, bolt circle diameter and flange
thickness.
• Total weight.
- The heaviest maintenance component weight and name of the part that
must be lifted during dismantling.
• Direction of rotation.
GENERAL SPECIFICATIONS
• Wiring diagram for each auxiliary system supplied, such as RTDs, vibration
sensors, space heaters and instrument devices.
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
APPENDIX A
DATA SHEET