SPECIFICATION FOR [STANDARD SPECIFICATION NO. eet PE SRAKi HIGH VOLTAGE 6-51-0033 Rev. 3 ES Sw tearm ners SYNCHRONOUS MOTORS Page 1 of 19 seq alee Wastes Fret @ fore fatter SPECIFICATION FOR HIGH VOLTAGE SYNCHRONOUS MOTORS REVISED AND ISSUED AS STANORAD 1 rh — 3250408 SPECIFICATION anesFee AG sys 4 REVISED AND ISSUED AS STANGRAD 2 0305 REVISED AN som AN VPS —~—=KG RE-RIED AND ISSUED AS STANOARD 7 eoorar _REFIRMED AND a a eS 0 R2A18 ISSUEDAS STANDARD SPECICATION MP ~OUKPSSC : — ‘Standards Standards 7 vepared chested Commitee Burcu Ree ate Purpoee Prpared checked Convoy _chalinan ‘Approved by Format No, 8-00-0001-F1 Rev. ‘Copyright EIL- Allrights reservedions: AC BIS BS BID CACA cACW CIMFR cr a pe pcs SPECIFICATION FOR ‘STANDARD SPECIFICATION NO. HIGH VOLTAGE 6-51-0033 Rev. 3 SYNCHRONOUS MOTORS eae Alternating Current Bureau of Indian Standards British Standards Bearing Temperature Detector Closed circuit cooling with air to air heat exchanger Closed circuit cooling with water to air heat exchangers, Central Institute of Mines and Fuel Research (formerly CMRI, Current Transformer Flameproof type -explosion protection Direct Current Distributed Control System Increased safety type ~explosion protection Factory Mutual Research Corporation High Rupturing Capacity Input/Output Intemational Electrotechnical Commission Institute of Electrical and Electronics Engineers Ingress Protection, Indian Standards Japanese Electro-technical Committee Laboratoire Central des Industries Electriques Light Emitting Diode Miniature Circuit Breaker National Electrical Manufacturers Association Pressurised type ~explosion protection Power Factor Per Unit Permanent Magnet Generator Purchase Order Potential Transformer Poly Vinyl Chloride Root Mean Square Resistance Temperature Detector Underwriters Laboratories ‘Verband Deutscher Elecktrotechniker Electrical Standards Committee Convenor: Members: Mr. Mr. Mr. Mr. Mr. Mr. Mr. Mr. Mr. JM. Singh N. Sethi UA. Patro S.S. Manhas ‘Arun Kumar BRR. Bhogal S. Kaul Projects) R. Mahajan (PEM) S.K. Dhawan (Inspection) Format No. -00-000-F1 Rev. 0 ‘Copyright Ell — Alrights reserved10 20 3.0 40 50 60 70 8.0 9.0 10.0 110 120 13.0 140 15.0 Stor SPECIFICATION FOR ar, Te OR LIMITED HIGH VOLTAGE it sna SYNCHRONOUS MOTORS CONTENTS SCOPE CODES AND STANDARDS GENERAL REQUIREMENTS. OPERATING CONDITIONS PERFORMANCE, CONSTRUCTION DETAILS CONTROL, ALARM AND TRIP DEVICES EXCITER AND RELAY PROTECTION PANEL MISCELLANEOUS ACCESSORIES NOISE LEVEL MOTOR VIBRATIONS, CRITICAL SPEED INSPECTION, TESTING AND ACCEPTANCE CERTIFICATION PACKING AND DESPATCH ‘STANDARD SPECIFICATION NO. 6-51-0033 Rev. 3 Page 3 0f 19, Format No. 8-00-0001-F1 Rev. 0 ‘Copyright EIL— All rights reservedENGINEERS, SPECIFICATION FOR ‘STANDARD SPECIFICATION NO. site INDIA UMITED. HIGH VOLTAGE 6-51-0033 Rev. 3 area ow einem SYNCHRONOUS MOTORS Page 4 of 19, 1.0 SCOPE ‘This specification covers the design, manufacture, testing, packing and supply of High Voltage Synchronous Motors and the excitation panel. 2.0 CODES AND STANDARDS 2.1 The equipment shall comply with the requirements of latest revision of following standards issued by BIS unless other specified: Is:5 Colors for ready mixed paints and enamels, Is: 325 Three phase Induction Motors. IS:1076 Preferred numbers IS:1271 ‘Thermal evaluation and classification of Electrical insulation, IS: 2071 Method of high voltage testing. 1S: 2148 Flameproof enclosures of electrical apparatus. 1S:2253 Designation for type of construction and mounting arrangement of rotating electrical machines. IS:3700 Essential rating and characteristics of semi conductor devices. Is : 4691 Degrees of protection provided by enclosure of rotating electrical machinery. 18:4722 Rotating electrical machines 1S:4728 Terminal Marking and direction of rotation for rotating electrical machinery. IS: 4889 Method of determination of efficiency of rotating electrical machines. 18:6297 Transformers and indicators for electronic equipment. 1S: 6362 Designation of method of cooling of rotating electrical machines. IS:6381 Construction and testing of electrical apparatus with type of protection ‘e’ IS:7132 Guide for testing of synchronous machines. IS: 7306 Methods for determining synchronous machine quantities from tests. IS: 7389 Pressurized enclosure of electrical equipment for use in hazardous areas. 18: 7816 Guide for testing of insulation resistance of rotating machines. 1S: 8223 _Dimensions and output series for rotating electrical machines. 1S: 8289 Electrical equipment with type of protection ‘n” IS: 12065 Permissible limits of noise level for rotating electrical machines. 1S: 12075 Mechanical vibration of rotating electrical machines with shaft heights 56 mm and higher - measurement, evaluation and limits of vibration severity 1S: 12802 Temperature rise measurement of Rotating Electrical Machines. 18: 12824 Type of duty and classes of rating assigned to rotating electrical machines. IS: 13408 Code of practice for the selection, installation and maintenance of electrical ‘apparatus for use in potentially explosive atmospheres. IS - 14222 Impulse voltage withstands levels of rotating electrical machines with form- wound stator coils. IS- 14568 Dimension and output series for rotating electrical machines, frame numbers 355 to 1000 and flange numbers 1180 to 2360. 2.2, In case of imported equipment, standards of the country of origin shall be applicable, if these standards are equivalent or stringent than the applicable Indian standards. 23 The equipment shall also conform to the provisions of Indian Electricity rules and other statutory regulations currently in force in the country. 24 In case Indian standards are not available for any equipment, standards issued by IEC/ BS/ VDE/ IEEE/ NEMA or equivalent agency shall be applicable. 25 In case of any contradiction between various referred standards specifications/ data sheet and statutory regulations the following order of priority shall govern Format No, €-00-0001-F4 Rev. 0 ‘Copyright EL — Al ights reservedSSR ay ENGINEERS, SPECIFICATION FOR ‘STANDARD SPECIFICATION NO. sed tree @ RIA UMITED HIGH VOLTAGE 61-0033 Rev. 3 — cone ere SYNCHRONOUS MOTORS 3.0 BA 32 33 40 41 42 42.1 42.2 423 43 Page 5 of 19 - Statutory regulations - Data sheets - Job specification - This specification = Codes and standards GENERAL REQUIREMENTS The offered equipment shall be brand new with state of the art technology and proven field track record. No prototype equipment shall be offered. Vendor shall ensure availability of spare parts and maintenance support services for the offered equipment at least for 15 years from the date of supply. ‘Vendor shall give a notice of at least one year to the end user of equipment and EIL. before phasing out the product/spares to enable the end user for placement of order for spares and services. OPERATING CONDITIONS Ambient Conditions Motors shall be suitable for operating satisfactorily in humid and corrosive atmospheres found in refinery, fertilizer, petrochemical and metallurgical plants and site conditions as specified in the data sheets. If not specifically mentioned therein, a design temperature of 40 °C and an altitude not exceeding 1000 metres above mean sea level, shall be taken into consider Frequency and Voltage V: tions Unless otherwise agreed, motors shall be required for continuous, satisfactory operation at rated output under the following conditions: At rated frequency with voltage variations of + 6 % of nominal value. At rated voltage with frequency vari ns of + 3 % of nominal value. Starting Unless otherwise specified, motors shall be designed for direct on voltage. starting across full Hine Motor shall be designed to allow the minimum number of starts indicated in Table below. The permissible number of starts shall be displayed on the motor in bold letters to safeguard the ‘motor against excessive number of starting STARTING CONDITION MINIMUM NO OF STARTS Upto 500kW | 500 to1000kW | Above 1000 kW No. of consecutive stari-ups with 3 3 2 initial temperature of the motor at ambient level (cold) No. of consecutive start-ups with 2 2 T initial temperature of the motor at full [oad operating level (hot) Format No, 8-00-0001-F1 Rev. 0 Copyright EIL— Al ights reservedENCRERS ‘SPECIFICATION FOR STANDARD SPECIFICATION NO. SAAD HIGH VOLTAGE 6-51-0033 Rev. 3 TGS ea dearer SYNCHRONOUS MOTORS Page 6of 19 44 48 46 47 48 49 5.0 Sa 52 53 54 6.0 6.1 6.1.1 Unless otherwise stated in the data sheet, motors shall be suitable for starting at 80 % of the rated voltage. Unless otherwise agreed, Locked rotor withstand time hot under condition at 100% voltage (time te in case of increased safety motors) and at 80% voltage shall be at least 20% more than the starting time at 100% and 80% respectively under specified load conditions, However minimum value of te shall not be less than 5 seconds. In case the locked rotor withstand time is less than the starting time or te, provision of speed switch etc. shall be mutually discussed and agreed between manufacturer and EIL/Owner. Starting torque and minimum torque of the motor shall be compatible with the speed torque characteristics of the driven equipment under specified starting and operating conditions. However starting torque of the motor at 80% voltage or minimum starting voltage as specified shall be at least 20% more than the starting torque of the driven equipment. The pull out torque at rated voltage shall not be less than 175% of the rated load torque with no negative tolerance. In case of motors driving equipment with pulsating loads such as reciprocating compressors, ball mills, crushers etc., the minimum value of the pull out torque at 80% of the rated voltage shall be more than the peak value of the pulsating torque and current pulsation shall be limited to 40%, Direction of Rotation Motors shall preferably be suitable for direction of rotation to suit the requirement of driven equipment. Normally, clockwise rotation is desired as observed at facing the driving end when the terminals marked as per IS : 4728 are connected to a supply giving a terminal phase sequence corresponding to the alphabetical sequence of the terminal letters. Directional arrow plate shall be manufactured from corrosion resistant material System Earthing Unless otherwise specified the motor insulation shall be suitable for resistance earthed system. PERFORMANCE Motors shall be rated for continuous duty (S1) unless otherwise specified and shall run at constant synchronous speed under any load conditions. The starting current shall be as specified in the motor data sheet. If not specifically mentioned therein, starting current shall be 500% subject to IS/ IEC tolerance for motors up to 1000 kW. For motors above 1000 kW, it shall be agreed with purchaser for each case. ‘Motors shall start as an induction motor. Damper windings shall be adequately designed for starting requirement. In particular cases, where starting with reduced voltage is specified or starting current is to be limited, care shall be taken such that the design values of torque meets the load requirement while at the same time complying to technical requirements specified above in this specification. CONSTRUCTION DETAILS ‘Winding Insulation and Bracing Synchronous motors shall be provided with class F insulation unless otherwise specified in the data sheet. The permissible temperature rise by the resistance method, above the specified ambient temperature shall be limited to class-B insulation. Format No, 8.00-0001-F1 Rev. 0 ‘Copyright EIL— Al rights reservedSoil > NERS IRSA LINED HIGH VOLTAGE 6-51-0033 Rev. 3 abece ROAM ‘SYNCHRONOUS MOTORS s 6.1.2 613 6.1.6 62 621 6.22 624 625 62.6 627 628 629 SPECIFICATION FOR ‘STANDARD SPECIFICATION NO. Page 7 of 19 ‘The windings shall be tropicalised and vacuum impregnated. Windings shall be adequately braced to prevent any relative movements during operating conditions. Core laminations shall be capable of withstanding bumout for rewind at 400 °C without damage or loosening. In case of motors driving equipment with pulsating loads, special attention shall be paid to the joints of rotor bars and end rings to avoid premature failures due to induced fatigue stresses. Windings shall be designed to withstand a coil surge voltage of 2.4 p.u. rated peak line-to-line voltage. Motor shall be designed to withstand impulse voltages specified in the applicable standards. Windings of motors shall be star connected. ‘Terminals, Terminal Boxes and Cable Entries The end of the windings shall be brought out into a terminal box. The terminations shall be by means of bushings with adequately sized bolted terminals. Line terminals shall be properly insulated from the frame with material resistant to tracking. The main terminal box shall be located on the right hand side as viewed from driving or the coupling end. Unless otherwise specified, the terminal box shall be suitable for bottom cable entry. The size of the cable end boxes shall be large enough to provide a minimum distance between cable gland plate and terminal lug of 600 mm for motors rated upto 6.6 kV and 750 mm for motors rated above 6.6 kV upto 11 kV. The neutral point of the star windings shall also be brought out to a separate terminal box. ‘This shall house the current transformers required for the motor and shall be located on the opposite side of the main terminal box. ‘The main terminal box shall be of fabricated sheet steel and shall be phase-segregated type / phase insulated type unless otherwise agreed. In case phase segregated /phase insulated type design is not feasible, air insulated type design with elastimould connector arrangement having, proven track record and required type test certification shall be considered and same is subject to acceptability by ElL/Owner. In such case, the terminal box shall be supplied complete with elastimould connector and all required accessories. The terminal boxes must be of robust construction, with necessary clearances’ creepage distance between live parts and between live parts to earth considering air insulation and without any compound filling. The terminal box shall be provided with pressure relief flaps! devices for increased safety and safe area motors, as per manufacturer's standard, ‘The main terminal box shall be suitable for withstanding, the specified fault level for a ‘minimum period of 0.25 seconds, Appropriate phase marking as per relevant standards shall be provided inside the terminal box. ‘The marking shall be non-removable and indelible. Equipment and accessories provided shall conform to the hazardous area classification or safe area as specified in the data sheet. ‘An adequately sized earth terminal shall be provided inside the main terminal box for cable armour termination, Bonding straps are required to be provided across joints on non-active parts. Format No. 8:00-0001-F Rev. 0 ‘Copyright EIL— All rights reservedSGHAZRE gy ENGINEERS. SPECIFICATION FOR [STANDARD SPECIFICATION NO. eBareiaes @ NA UNITED HIGH VOLTAGE 6-51-0033 Rev. 3 Senos Hon shaetneg SYNCHRONOUS MOTORS Page 619 6.2.10 Appropriate phase markings as per IS: 4728 shall be provided inside the terminal box. The 6211 6.2.12 63 63.1 63.2 633 63.4 64 641 ‘markings shall be non-removable and indelible. Separate terminal boxes shall be provided for space heaters, resistance temperature detectors, vibration probes, current transformers ete. Main and Neutral terminal box covers must be provided with handles to facilitate easy removal. Motor Casing and Type of Enclosure Motors for use in hazardous areas (Zone-1 ot Zone-2) shall have type of protection Ex (4) or Ex (e) or Ex (p) as specified in the data sheet and shall meet the requirements of applicable standards. Al motors shall be suitable for installation directly outdoor unless other wise specified and must have a degree of protection corresponding to IP - 55 as per IS. Motor casing shall be provided with a suitable drain for removal of condensed moisture. All internal and external metallic parts which can come into contact with cooling air, (Piping, air supply and discharge conduits, protective grills, air deflectors, supports etc.) shall be of corrosion resistant material or appropriately treated to avoid corrosion by gases present in the atmosphere. Effective equi-potential bonding straps to guard against the occurrence of sparks due to presence of circulating currents shall be provided for all motors required for hazardous area application, Bearings and Lubrication General a, Motors shall have grease lubricated ball or roller type bearings or of the manufacturer's standard type. However 2 pole motors above 750kw rating shall be provided with sleeve bearings as a minimum except for flameproof motors required for gas grotip-IIC. Sleeve bearings when provided shall be of proven design. b. Lis chosen to give a minimum L-10 rating life of 5 years (40000 hrs) at rated operating, conditions (The L-10 rating life is the number of hours at constant speed that 90% of a group of identical bearings will complete or exceed before the first evidence of the failure). Where bearing supports are attached to the motor casing, adequate bracing shall be provided on these supports to reduce vibrations and ensure long life of the bearings. Bearings shall be adequate to absorb axial thrust produced by the motor itself or due to shaft expansion, 4d, Motor bearings exposed to high temperature shall have adequate provision for cooling of bearings. €. Vertical motors shall be provided with thrust bearings suitable for the load imposed by the driven equipment. £. Motors shall be designed to permit removing/ replacement of bearings at site. Format No, 8-00-0001-F1 Rev. 0 ‘Copyright EIL— Al nights reservedINEERS, SPECIFICATION FOR ‘STANDARD SPECIFICATION NO. SR SRA UMITED HIGH VOLTAGE 6-51-0033 Rev. 3 Soret oer etna nay SYNCHRONOUS MOTORS Page 9of 19 6.4.2 Grease lubricated bearings 643 64.4 Bearings shall be capable of grease injection from outside without removal of covers. The bearings boxes shall be provided with labyrinth seals, to prevent loss of grease or entry of dust or moisture. When grease nipples are provided, these shall be associated, where necessary, with appropriately located relief devices, which ensure passage of excess grease through the bearings. The motors shall have facility for on-line greasing. Self-Iubricated oil bearings Sleeve type bearings shall be fitted with oil rings for continuous lubrication. The oil reservoir shall have a form suitable for allowing settling of any solids or residual particles contained in the oil ‘The covers shall be provided with suitable openings for adding and draining oil, together with an overflow plug and level indication, The shaft shall have perfect seals so as to prevent entry of dust or moisture. Forced lubrication bearings The oil lubrication system shall be independent of the driven machine. Common lubrication system for the driven equipment and the motor can be accepted provided it is separate from the seal oil system. In the independent lubrication system, oil supply shall be guaranteed by one of the following systems: With a mechanical pump co-axial with the motor and supplemented by a separate electric motor driven pump for initial lubrication during start up and stopping operations. - With a separate electric motor driven pump. In this case the lubricating system shall consist of two identical motor driven pumps, one running and one acting as standby. In addition to the pumps, the lubrication system shall be supplied complete with the following as a minimum. Externally mounted oil cooler. b. An stainless stee! oil reservoir with the following characteristic: - The capacity to avoid frequent filling, to provide adequate allowance for system rundown and to provide a retention time of at least 3 minutes to settle. - A bypass line that retums below the oil level to eliminate aeration and static electricity = Sight flow indicators, Temperature gauges, pressure gauge, Low oil pressure alarm and shutdown switches ete. ~ A thermostat with two electrical contacts for alarm and tripping in case of high oil ‘temperature ¢. Automatic/manual control system for the pumps shall be provided to start automatically on low oil pressure and with manual shutdown only. 4, Thermostatically controlled electric immersion heater ‘A control panel shall be provided for operation and control of the lubrication system. The control panel shall include fuses, electrical contactors and thermal relays for the protection and operation of the motor driven pumps, push-buttons, auxiliary relays and timer relays for the automatic and manual starting up and shutting down of the oil pump. Potential free contacts for repeat signals for interface with DCS shall be provided as per approved process and instrumentation diagram. Format No, 8-00-0001-F1 Rev. 0SMES fy ENGINEERS SPECIFICATION FOR STANDARD SPECIFICATION NO. sar INDIA LIMITED HIGH VOLTAGE 6-51-0033 Rev. 3 EO Nemes SYNCHRONOUS MOTORS Page 10.1 19 Equipment and accessories provided shall conform to the hazardous area and the mental conditions specified in the data sheet. 64.5 Bearing insulation-shaft voltage Induced voltage at the shaft end of the motor at no load shall not exceed 250 mV rms. for roller and ball bearings and 400 mV r.m.s. for sleeve bearings. The non-driving end bearing shall be insulated from the motor frame to avoid circulating current. The insulated bearing end shield or pedestal shall bear a prominent warming, 65 Cooling System All motors shall preferably be self-ventilated. Motors with higher outputs having manufacturer's standard designs using forced ventilation cooling or closed circuit cooling employing external coolants, may also be considered. 65.1 Self ventilated motors All motors shall be fan cooled. The fans shall be of corrosion resistant material and appropriately protected. For fertilizer plants, brass or bronze are not permitted materials. The material of fan for motors to be used in hazardous areas shall be anti-static and non-sparking type. Motors for installation in dusty atmospheres or in the presence of sand, fuels or other suspended solid particles in the air shall be fitted with filters for the cooling air. The filters shall be easily accessible for inspection and removable for cleaning and re-use. The material of the filters and supports trays shall be rust proof or protected against oxidation or corrosion. 6.5.2 Motors with foreed ventilation 653 65.4 Motors with forced ventilation shall be equipped with two motor driven fans each capable of supplying the full quantity of cooling air required by the motor at full load. The ventilating system shall include the flanges for the air intake and the mating flanges for the discharge ducts. Air intake shall be from safe area. Motors and fans used for forced ventilation shall conform to the hazardous area classification and environmental conditions specified in the data sheet. Motors with closed circuit cooling with water to air heat exchangers (CACW) ‘The material of the heat exchangers shall be corrosion resistant (e.g. cupro-nickel alloy, muntz, metal, admiralty brass) and suitable for the type of water used. The heat exchangers shall be designed for a minimum water pressure of § kp/ em? and with head losses not greater than 0.5 kg/em Screens shall be provided to protect the motor windings from water leaks or leakage in the tubes. Isolation valves at the entry and exit point shall be provided. Suitable drains shall be fitted for draining water in case of leakage. The cooling system shall include the trip and alarm devices mentioned in the specification. Pressure gauge at delivery ‘end shall be provided. Heat exchangers of identical motors shall be interchangeable. Motors with closed circuit cooling with air-to-air heat exchangers (CACA) All exposed surfaces of the heat exchanger and of the motors shall be protected against corrosion, Format No, 8-00-0001-F1 Rev. 0 (Copyright EL ~ Al rghts reservedGRRE My ENGINEERS SPECIFICATION FOR ‘STANDARD SPECIFICATION NO. sear TON UMITED: HIGH VOLTAGE 6-51-0033 Rev. 3 SE Resor sonra ‘SYNCHRONOUS MOTORS Page 1 of19 6.6 67 611 6.7.2 673 6.14 6.15 Weatherproof gaskets shall seal joints between the heat exchanger and the main body of the motor. Filters shall be provided as required to prevent the ingress of dust and foreign particles. These shall be easily accessible, for cleaning and replacement. Rotor Rotor shall be made in one piece with complete cage of dampers to permit starting as induction motor. Windings shall be of copper and shall be treated in the same way as the stator winding. Rotor coil insulation shall offer high resistance to moisture, water and chemicals suitable for use in specified atmosphere. Rotor shall be dynamically balanced to provide a low vibration level and a long service life to the bearings. ‘The shaft ends shall be provided with suitably threaded hole or holes to facilitate the assembly or removal of couplings and bearing races. Excitation System The synchronous motor shall have brush less excitation system. The excitation system shall consist of the main field winding of the motor, AC exciter and rotary rectifiers, discharge resistors, control cireuit ete. The AC voltage generated by the AC exciter shall be rectified by the rotary rectifier assembly and fed to the main field circuit of the synchronous motor. The rectifier shall preferably consist of a number of diodes / thyristors connected as three phase bridge. The bridge shall be adequately protected to ensure automatic isolation of a short- circuited electronic device. The presence of faulty equipment shall also be indicated either by aLED orarelay. ‘The rotor winding of the AC exciter, the rectifier assembly, main field winding of the motor and other accessories on rotor part shall be rigidly fastened to the shaft and the connection between the individual items shall have anti loosening type connecting leads. The exciter capacity shall be at least 20 % more than the maximum requirement at any time. The excitation system of the motor shall be compatible with the drive system. The power factor of the system shall be available from 0.95 pf. (Lag) to 0.95 p.f. (Lead) unless otherwise specified. Short time line interruptions up to 200 m secs. shall not cause the drive control system to drop ‘out or have any adverse effect on the system operation. AC exciter a. The AC exciter shall be a three phase synchronous generator with a rotary armature type design. Its stator shall be constructed so that the magnetic pole is bolted to the magnet frame. The magnetic pole shall be made of laminated punched sheet steel. Its rotor shall be constructed so that the armature windings are installed in slots of the armature core. b. Rotating AC exciter shall have stationary field current powered by a PMG, c. In case PMG cannot be offered by motor manufacturer as standard design, the system shall be designed for external power supply as follows: The external power supply shall be provided by Purchaser from 2 Nos. 415 V, 50 Hz AC power sources. If power from one source fails, changeover shalll take place to the other supply. Auto-Manual change over scheme shall be provided in the Excitation Panel for the same, Changeover of the 415 V excitation supply from one to another shall not cause tripping of machine. Format No, 8-00-0001-F' Rev. 0 ‘Copyright EIL— Al rights reservedSSRZET By ENGINEERS, SPECIFICATION FOR ‘STANDARD SPECIFICATION NO. INDIA LIMITED HIGH VOLTAGE 6-61-0033 Rev. 3 SS Oe Naat SYNCHRONOUS MOTORS Page 1201 19, 6.7.6 6.7.7 68 6.9 6.10 70 TA 72 Class F insulation material with Rotary rectifier ‘The rotary rectifier set shall consist of thyristors/diodes, fuses, resistors, condensers ete, The equipment shall be highly reliable. Adequate over current and over voltage protection shall be provided. A discharge resistor shall be applied in the field circuit to protect abnormal voltage induced in the field coil during starting. The circuit components shall be properly selected for ‘optimum operation. The circuit components shall be manufactured and so arranged as to give ‘maximum protection against the effect of vibration, dampness and corrosion. The elements built into the rotary rectifier shall offer very high reliability and long life, assuming trouble free operation with practically no maintenance requirement. Even when one of the parts malfunctions, replacing only the defective part can continue operation. Provision shall be made to cut off excitation system in case of fault inside the motor. Shaft Extension Motors shall be provided with a single, bare-shaft extension with key-way and key Lifting Hooks All motors and the associated heavy accessories shall be provided with lifting facility of adequate capacity. Earth Terminals ‘Two earth-terminals shall be provided on the frame of each motor at diametrically opposite Minimum size of earthing stud shall be 12 mm. One separate earth terminal shall be provided inside the terminal box for earthing of the armour. Necessary nuts and sprit ‘washers shall be provided for earth connection. CONTROL, ALARM AND TRIP DEVICES ‘The electrical contacts for various devices shall be rated for min. 5 Amps at 240 V AC (AC-15 duty) and 2 Amps at 220 V DC (DC-13 duty). The contacts shall be located in a flameproof enclosure or totally sealed housing according to the type of motor enclosure. The cable ends shall be brought together to one or more terminal boxes. Individual cable boxes shall be provided for power and control cable. Any extemal connections between the housing containing the relay contacts and the terminal box shall be carried out in steel conduits or affected by PVC insulated and armoured cables. Measurement of Winding Temperature Motors with outputs greater than 1000 KW or those provided with filters for cooling air irrespective of output shall be provided with platinum resistance temperature measuring devices of 100 Ohm resistance at 0° and a temperature coefficient of 3.85 x 10 * located in suitable positions to measure the winding temperatures. A minimum of three (one per phase) temperature detectors shall be provided between the coil sides to measure the winding temperature and three (one per phase) at the base of the slots to measure core temperature each placed 120 degrees apart. Measurement of Bearing Temperatures Motors with sleeve type bearing shalll be provided with: Format No, 8.00-0001-F1 Rev. 0 Copyright IL Al ights reservedSPECIFICATION FOR ‘STANDARD SPECIFICATION NO. INEERS ates SRA HIGH VOLTAGE 6-51-0033 Rev. 3 Sen a aan SYNCHRONOUS MOTORS meiera 73 74 78 a. Two mercury bulb type, indicating, dial thermometers for checking of bearing temperature, b. For motors with outputs greater than 1000 kW, a resistance type of temperature measuring, device shall be provided for bearings with connection terminating in the same terminal box used for winding temperature detectors. ©. Monitoring device for winding temperature and bearing temperature shall be common and included in the manufacturer’s scope unless otherwise specified. Alarm and trip contacts shall be made available for owners use separately for winding temperature and bearing temperature. Monitoring devices shall be mounted on the panel or supplied loose as defined in the data sheet. Measurement of Cooling Medium for Heat Exchangers Motors with forced ventilation and those with air water heat exchangers shall be provided with: 8. Airflow circulation indicator electrical trip contacts, which operate if the flow of cooling air, is interrupted or is inadequate. b. A cooling water flow circulation indicator with electrical trip contacts which operate if the flow of cooling water is interrupted or is inadequate, The indicator shall be located on the discharge piping of the heat exchanger. Lubrication Control Motors with forced lubrication shall be provided with: a. An indicating pressure gauge fitted on the oil supply Tine to each bearing, for local control or checking of the lubricating oil pressure. b. Pressure switches for the interlocks required at start-up for low lube oil pressure alarm and trip. ‘A temperature switch for high supply oil temperature alarm, ‘A local flow indicator on the oil discharge line. A thermostat for control of the electrical resistance heater provided for the oil ‘Temperature gauge for the temperature of the oil in the tank. Level switch for low-level alarm for lube oil tank. Differential pressure indicator across the filter FR me ao Pre-purging / Pressurisation Control Panel Pressurised motors Ex-p shall be provided with a control panel for controlling the initial purging and then pressurization of the motor. Automatic control system of purging and pressurization shall comprise of feeding unit, pressure control unit, outlet unit and logic control unit The pressurization control pane! shall be mounted on the motor itself .The offered equipment shall be suitable for the hazardous area classification specified in the motor data sheet. The panel shall be in flameproof execution execution complete including all accessories and material as required which shall not be limited to the following = Flameproof control panel components - Timers, Push button for purging and pressurisation = Solenoid valves and damper - Indicators for ON, OFF, low pressure etc. - Pressure switches and flow switches with alarm and trip contacts Potential free contacts shall be provided in the panel duly wired to the terminals for interfacing ith the electrical system/DCS system by others. Format No, 8-00-0001-F' Rev. 0 Copyright EI ~ Alrights reservedSize ENGINEERS fetistes SS INDIA LIMITED HIGH VOLTAGE 6-51-0033 Rev. 3 Sere SRO ‘SYNCHRONOUS MOTORS 8.0 81 82 83 83.1 83.2 833 84 841 SPECIFICATION FOR ‘STANDARD SPECIFICATION NO. Page 18 0f 19 EXCITER AND RELAY PROTECTION PANEL. General Generally high voltage cubicle for PT, excitation cum control panel shall be located in remote substation building approximately 400m away whereas pressurisation and lubrication panels shall be mounted locally near the motor unless other wise specified. The exciter panel shall permit easy maintenance and continuous uninterrupted operation over a long period and shall supply DC excitation to the AC exciter used in the brush less synchronous motor. The DC source is obtained by rectifying three-phase/single phase AC source. The cubicle shall contain. rectifiers, auxiliary transformers and excitation control circuitry. Construction The panel shall be composed of free standing, dust and vermin proof type and constructed of steel plates and steel angles bolted or welded together. Minimum degree of enclosure protection shall be IP-31 Alll cable connections shall be from bottom. All incoming and outgoing control cables shall be terminated in a terminal block. 20 % spare terminals are to be kept in the terminal block and terminals shall be suitable for 2.5 mm? conductor. All switches, indicating lamps/LEDs, selector switches and setting devices shall be mounted on the front. ‘Components All control circuits shall be made on modular concept and shall be with static components mounted on printed cards. If any of these cards malfunction these shall be replaceable. All control circuits shall use uniform operating signal (voltage) level. ‘This panel shall house all protective relays for the motor and excitation system e.g. composite motor protection relay and motor differential relay if specified in the data sheet, field failure relay, rotor earth fault relay, out of step relay, field over current relay, field over voltage relay etc. as may be necessary for safe operation of the excitation scheme. All trip contacts shall be wired to the terminal block and alarm contacts should be wired separately. At least following conditions should be annunciated in the exciter panel: “Field Failure’, Field Over current’ and "Exciter Pane! Supply Trip’ and indicating lamps! LEDs shall be provided showing "Excitation On’ and ‘Fault Trip’. Solid-state annunciator shall be used. Excitation Control The excitation control of the synchronous motor shall be affected by controlling the excitation current of the AC exciter from the exciter panel The control shall be achieved both by manual and automatic modes. There shall be a selector switch to select the particular mode. Excitation control schemes as specified below shall be followed. a. Constant power factor control In this mode the operating power factor of the synchronous motor can be set at a constant value (within the rated power factor value of the machine). As the load is changed or as system conditions change the excitation control automatically compensates so that the power factor angle is maintained constant. b. Constant reactive power control With this type of control the reactive power output of the synchronous motor remains constant at all loads. Operating point is established by a manual set point. Format No. 8-00.0001-F'1 Rev. 0 ‘Copyright EIL— Allighis reservedSPECIFICATION FOR ‘STANDARD SPECIFICATION NO. SGML (ENGINEERS, eat OND UMITED. HIGH VOLTAGE 6-51-0033 Rev. 3 Temasek an tsesinenes SYNCHRONOUS MOTORS 842 843 844 845 8.4.6 847 90 94 92 93 Page 15 0f 19 The setting devices should be mounted at accessible position and should be properly calibrated to facilitate proper setting. The devices should be lockable at the set point. All power measuring active and reactive transducers and comparator circuit shall include reliable solid-state components. Microprocessor based digital type control; monitoring, protection and status scheme may be included as per manufacturer's proven standards. The offered system shall have provision for interface with upper level automation system through RS232/ 485 ‘One set of potential free contact of remote breaker ON/ OFF/ TRIP etc. shall be made available at the exciter panel by others. These contacts shall be multiplied by the vendor in case additional contacts are required for interlock, startup, tripping ete. Excitation system shall have the LED indication for selection of auto and manual control and necessary potential free contacts for the selection shall be wired up to the terminal for remote indication. Also push buttons for closing and tripping of remote breaker shall be included. Exciter panel shall have provision for remote control, monitoring, status indication at purchaser's remote control panel. Any equipment/accessories like interfacing relays, W/O racks etc. shall be included as part of exciter panel. MISCELLANEOUS ACCESSORIES Current Transformers Unless otherwise specified, motors rated 1500 KW and above shall have differential protection and shall be equipped with current transformers suitably designed for installation in the terminal box. ‘The motor differential CTs shall be supplied along with the motor and mounted in the neutral terminal boxes. Current transformer for excitation system shall be included and mounted in the ‘motor terminal box. ‘These transformers shall have a secondary current of 1A, and the characteristies of the CTs (Vis Ret and Tq) shall be finalized at detailed engineering stage in consultation with the purchaser. CT ratio shall be as indicated in the motor data sheet. Anti-condensation Heaters ‘The motors and panels shall be provided with 240 V anti condensation heaters, sized and located so as to prevent condensation of moisture during shutdown periods. The motor space heaters shall remain ‘on! when the motor is not in service, and shall not cause damage to the windings. For motors installed in hazardous atmospheres (zone-1 or zone-2) such heaters shall conform to the provision of applicable standards and temperature classification specified in the data sheet. Motor space heater power supply shall be arranged from the exciter panel only with necessary on/off interlock with motor starting, ‘A warming label with indelible red inscription shall be provided on the motor to indicate that isolation of the power line alone is not sufficient and that the heater supply should also be isolated before carrying out any work on the motor. Special Tools and Tackles Motors with special features such as motors with single bearing, with explosion proof? increased safety type of protection; pressurised motors etc. shall be provided with a set of special tools as required for dismantling and maintenance of the motor. Format No, 8.00-0007-F1 Rev. 0 Copyright Elk. ~All righis reservede SPECIFICATION FOR ‘STANDARD SPECIFICATION NO. Bar, S| 94 98 96 97 10.0 11.0 12.0 HIGH VOLTAGE 6-51-0033 Rev. 3 one ‘SYNCHRONOUS MOTORS Page 16 of 19, Cable Glands and Lugs Motors and field mounted control panels shall be provided with double compression Nickel- plated Brass (or Aluminium, if specifically required) cable glands, crimping type tinned Copper cable lugs for all power, space heater and auxiliary cables (for the specified cable sizes) etc. Indoor mounted contro! panels shall be provided with single compression Nickel- plated Brass (or Aluminium, if specifically required) cable glands and crimping type tinned Copper cable lugs. Equipment to be installed in hazardous area shall be suitable for the specified area classification, Auxiliary Motors Auxiliary motors if any shall be as per relevant Indian/ International standards and shall be suitable for hazardous area classification as specified in the data sheet. Motors shall be complete with first filling of lube oil for forced lubricated bearings. Name Plate A stainless steel name plate manufactured from series 300 stainless steel and having information as per IS/IEC standards shall be provided on each motor. In addition to the motor rating plate, a separate motor plant equipment number plate (i.e. motor tag number) shall be fixed in a readily visible position. This number shall be as per the data sheets. Additional information as stipulated in applicable Standards shall be included in the nameplate for motors meant for use in hazardous atmospheres. Painting Internal and external parts of the casing and all metal parts likely to come in contact with the surrounding air shall be protected with anti-acid/anti-alkali, epoxy paint that will resist corrosion in the particular atmospheric conditions. All external surfaces shall be given a coat of epoxy-based paint. Paint shade shall be 631 and 632 as per Indian Standard IS-5 for indoor and outdoor ‘equipment respectively, unless otherwise specified. NOISE LEVEL The permissible noise level shall not exceed the stipulations laid down in applicable standards. MOTOR VIBRATIONS Motor vibrations shall be within the limits of applicable standards unless otherwise specified for the driven equipment. Limits of shaft vibration for motors with sleeve bearings shall be as per IEC-60034-14. Motors with sleeve bearings shall be provided with proximity probes to ‘measure the shaft vibration adjacent and relative to the bearings. Vibration detectors shall be provided for both horizontal and vertical direction at each bearing. CRITICAL SPEED ‘The first critical speed of rotors shall not be lower than 125% of the synchronous speed. Format No, 8-00-0001-F1 Rev. 0 ‘Copyright EIL— All ights reservedSGT fy ENGINEERS, SPECIFICATION FOR STANDARD SPECIFICATION NO. awe ONAiD HIGH VOLTAGE 6-51-0033 Rev. 3 Sniensoe aerana am ‘SYNCHRONOUS MOTORS Pago 17 0f 19 13.0 INSPECTION, TESTING AND ACCEPTANCE 13.1 During manufacturing of motors, the motors shall be subject to inspection by ElL/Owner’s Inspector or by an agency authorized by the Owner. The manufacturer shall provide all necessary information concerning the supply to EIL/Owner’s Inspector. 13.2 All the type and routine test shall be witnessed by the Inspector. The vendor shall give prior notice of minimum 4 weeks to the Inspector for witnessing the tests. 13.3 All the type and routine tests shall be carried out at manufacturer’s shop. 13.4. The manufacturer shall submit all internal test records of the tests carried out by him on the bought-out items, motor sub-assembly and complete motor assembly to the Inspector before offering the motors for final inspection and testing. 13.5 Type tests shall be carried out on one motor of each rating and frame size. 13.5.1 Type tests The following type tests shall be carried out as per applicable standards and shall form part of acceptance testing a. Full load test and measurement of voltage, current, power, slip b, Insulation resistance test before and after high voltage test on synchronous motor stated winding, field circuit (AC exciter), exciter panel AC and DC circuit ¢. Measurement of starting torque, starting current, full load torque and pull out torque. 4d, Measurement of efficiency and power factor at 100%, 75% and 50% load. €. Hydraulic test for coolers, if provided. f. Measurement of noise. g. Measurement of vibrat h, Temperature rise test i, Momentary overload test. J. Tan delta test. k, Over speed test. 1. Measurement of radial air gap. m, Polarisation index test. nn, Measurement of surface temperature of frame and space heater. ©. Measurement of resistance of space heater, RTDs and BTDs. p. No load saturation test q. Three phase short circuit test.. r. Vourve characteristics determination, 13.6 Routine Tests Routine tests shall be carried out on all motors. ‘The manufacturer shall carry out routine test as per applicable standards. Routine tests not limited to the following shall form part of acceptance testing a. General visual checks, name plate details, mounting, terminal box location and cable gland sizes b. Insulation resistance test for stator and rotor circuits and exciter (Before and after high voltage test) ©. High voltage test. |. No load test and measurement of voltage, speed, current and power input. €. Locked rotor test at reduced voltage and measurement of voltage, current and power input. Format No, -00-0001-F1 Rev. 0| Copyright EIL— Allrghts reservedSRS ae SGN HIGH VOLTAGE. 6-51-0033 Rev. 3 SPECIFICATION FOR STANDARD SPECIFICATION NO. RNAS nominee SYNCHRONOUS MOTORS Page 18 of 19 13.7 13.8 139 140 Reduced voltage starting and running Testing of accessories / auxiliaries for correct functioning. Resistance of stator winding and field winding to be recorded. Measurement of bearing current / shaft voltage. Phase sequence. Operation of control panel for Ex-p motor Tests on the Ex-d enclosures as per applicable standard Measurement of shaft center height dimensions Measurement of clearances in the terminal box Verification of type of terminals (for Ex-e, Ex-p) Verification of direction of rotation Verification of cooling system & lubrication system Exciter panel Feposgorcrse i, Check functioning of relays, interlocks, indication, alarm devices and different types of controllers. ‘Measure input AC and output DC voltages. i. Functional tests on the panel. iv, General check (overall and mounting dimensions, cable entries). s: Vibration measurement (with half key). The manufacturer shall submit the following certificates for verification by the ElL/Owner's Inspector: Test certificate for degree of protection of enclosure Short circuit test for terminal box Impulse test certificate Test certificates issued by the recognized independent test house for purging and pressurisation system of pressurised motors e. Test certificates issued by the recognized independent test house for hazardous arca motors £. Approval certificates issued by Indian Statutory Authorities for hazardous area motors &. BIS license and marking as required by Statutory Authorities for Ex-d motors and other Ex-d equipment manufactured in India. h, Hydraulic test certificate for coolers. ee oP In case any of the Type & Routine tests mentioned above cannot be carried out due to manufacturer's test bed limitatiohs etc., alternatively calculations to establish the required parameters as per International codes e.g. IEC, JEC etc. may be accepted which shall be furnished to attending inspector. Though the motors will be accepted on the basis of the satisfactory result of the testing at the shop, it shall not absolve the vendor from liability regarding the proper functioning of the motors coupled to the driven equipment at site. CERTIFICATION The motors and associated equipment shall have test certificates issued by recognized independent test house (CIMFR/ Baseefa/ LCIE/ UL/ FM or equivalent). All indigenous equipment shall conform to Indian Standards and shall be certified by Indian testing agencies. All equipment (indigenous and imported) shall also have valid statutory approvals as applicable for the specified hazardous location. All indigenous flameproof equipments and motors shall have valid BIS license & marking as required by statutory authorities. Format No. €-00-0001-F1 Rev. 0 Copyright Ei ~All ighis reservedSTE ay ENGINEERS, SPECIFICATION FOR STANDARD SPECIFICATION NO. eine OR UMITED HIGH VOLTAGE 6-51-0033 Rev. 3 Taman omnes SYNCHRONOUS MOTORS Page 19.0119 15.0 PACKING AND DESPATCH Al the equipment shall be divided into several sections for protection and ease of handling during transportation. The equipment shall be properly packed for transportation by selected mode of transportation i.e. ship/rail or trailer. The equipment shall be wrapped in polythene sheets before being placed in crates/cases to prevent damage to finish. Crates/cases shall have skid bottom for handling. Special notations such as ‘Fragile’, ‘This side up’, ‘Center of gravity’, ‘Weight’, ‘Owner's particulars’, ‘PO Nos.’ etc. shall be clearly marked on the package together with other details as per purchaser order. ‘The equipment may be stored outdoors for long periods before installation. The packing shall be completely suitable for outdoor storage in areas with heavy rains/high ambient temperature, unless otherwise agreed. Format No, 6-00-0001-F' Rev. 0 ‘Copyright EL — Al rights reserved