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Project MARMUL PUMP REPLACEMENT PROJECT
Client PDO
Vendor WEG
Material WEG MV VFD MVW3000
PO 4800012806
Report DAILY SITE SERVICE REPORT
SITE SERVICE REPORT
WEG MV VFD MVW3000 COMMISSIONING AT MARMUL, PDO
Site Details:
WEG Customer : AL ALAMIA/SPX
EPC Main Contractor : BEC
Project End User : PDO
Project Location : MARMUL, OMAN
Equipment Details : MVW3000 1200KW, 6.6 KV MV VFD 3 NUMBERS
Equipment Vendor : WEG
Service Required : Pre‐commissioning, Testing & Commissioning
Prepared By: N. Kamat Sign……………
Approved By: Sign……………
Date: 28/01/2020
1 of 9
SITE SERVICE REPORT
Project MARMUL PUMP REPLACEMENT PROJECT
Client PDO
Vendor WEG
Material WEG MV VFD MVW3000
PO 4800012806
Report DAILY SITE SERVICE REPORT
1. Scope of Work.
1.1. Installation supervision, pre‐commissioning, inter panel wiring, Power cell testing & inserting in the panel,
parameterize, testing and commissioning of 3 numbers of WEG MV VFD MVW3000 1200KW, 6.6 KV at PDO
Marmul site.
VSD panel tag MAR‐VSD‐24110, MAR‐VSD‐24111, MAR‐VSD‐24112,
2. Work carried out in brief.
Traveling from Muscat To Marmul.
Meeting with PDO, BEC to discussion SOW, planning & to get required tools &
manpower.
Day 2 13‐01‐2020 VSD‐24112
1. VFD panel visual inspection.
2. Panel front & rear side opened.
3. Panel cleaning done by Vacuum cleaner & air blower,
VSD‐24112
1. VFD panel Control & power cable inter panel wiring completed.
2. Power wiring tightness done, control wiring tightness in progress.
3. All VFD panel door were not closing properly. Door lock adjustment done.
4. Kirk Key lock is now working ok.
5. Power cell wooden packing opened. Power cell removed & started visual
Day 3 14‐01‐2020 inspection & cleaning.
VSD‐24111
1. VSD‐24111 Phase shift transformer Terminal B3A cleaned. Continuity & IR
checked ok.
Instrument cable not yet connected in panel.
Informed BEC to bring cable inside VFD & shown connection terminals.
VSD‐24112
1. All power cell visual inspection, cleaning, tightness done.
2. All power cell S1 DIP switch setting verified ok.
3. All Power cell inserted in the VFD panel.
Day 4 15‐01‐2020 4. Aux supply 3PH, 415VAC cable termination done.
5. Phase shift transformer all connection verified & tightness done.
2 of 9
SITE SERVICE REPORT
Project MARMUL PUMP REPLACEMENT PROJECT
Client PDO
Vendor WEG
Material WEG MV VFD MVW3000
PO 4800012806
Report DAILY SITE SERVICE REPORT
VSD‐24110
1. VFD panel cleaning done.
2. Inter‐panel power & control wiring done.
3. Power cable tightness done.
4. Phase shift transformer all connection done. Tightness verified.
5. Phase shift transformer IR test done with 1KV Megger.
6. All power cell visual inspection, cleaning, tightness done.
7. All power cell S1 DIP switch setting verified ok.
8. All Power cell inserted in the VFD panel.
9. Aux supply 3PH, 415VAC cable termination done.
VSD‐24111
1. All power cell visual inspection, cleaning, tightness done.
2. All power cell S1 DIP switch setting verified ok.
3. All Power cell inserted in the VFD panel.
4. Aux supply 3PH, 415VAC cable termination done.
5. Phase shift transformer all connection verified & tightness done.
Day 5 16‐01‐2020
6. VFD panel cleaning done.
7. Inter‐panel power & control wiring done.
8. Power cable tightness done.
9. Phase shift transformer IR test done with 1KV Megger.
10. All three VFD panel instrumentation cable (4 no’s cable for each VFD panel,
termination in progress.
1. Instrumentation cable termination at VFD panel side in progress.
Expecting to complete it by 18th Jan.
2. All three VFD panel Q0 isolator auxiliary contact status required to 6.6KV SWBD
Day 6 17‐01‐2020 CB for CB close permissive. VFD internal wiring done from Q0 isolator (Column‐1)
to VFD control section (Column‐4).
3. VFD to 6.6KV control cable connection explained to BEC. Required corrections
need to be done.
1. Instrumentation cable termination at all three VFD panel side completed.
2. Q0 isolator auxiliary contact VFD panel internal wiring completed for all three VFD
panel.
3. VSD‐24111 Pump 2‐ VFD panel phase shift transformer T1‐B3A terminal To
Inverter panel Power Cell V3‐ R phase cable found missing. Power cable is 16
Day 7 18‐01‐2020 mmsq 7.2KV, 6‐meter special flexible cable. This cable is from Column 2 to 3.
This issue is resolved. BEC gave 35mmsq 11KV cable. This cable laid & terminated.
IR value checked 50 G Ohm with 5KV megger.
WEG will send original 16mmsq 7.2 KV flexible cable 6 meter. Once cable
received, we can replace the cable. Till that time the temporary cable is ok to run
the VFD.
3 of 9
SITE SERVICE REPORT
Project MARMUL PUMP REPLACEMENT PROJECT
Client PDO
Vendor WEG
Material WEG MV VFD MVW3000
PO 4800012806
Report DAILY SITE SERVICE REPORT
4. 230V AC 2 no’s UPS supply & 3 Ph 415 supply cable continuity & IR test done for
all three VFD panel. 230V AC 2 no’s UPS supply & 3 Ph 415 supply is energized for
all three VFD panel.
5. 3 Ph 415 VAC feeder at LV SWBD for VFD panel was having 16 Amp fuse.
Requested BEC to change it with 32 Amp fuse. It is completed.
6. 6.6 KV VFD feeder protection setting document verified.
7. Visit done at motor & RCU.
8. All three VFD panel rear side covers closed & screw tightened.
9. All power cell serial numbers noted. VFD panel serial numbers noted.
1. All three VFD panel Q0 isolator one more auxiliary contact status required to
6.6KV SWBD Earth Switch for Earth Switch close permissive. VFD internal wiring
done from Q0 isolator (Column‐1) to VFD control section (Column‐4).
2. At RCU no wiring was connected. Cable termination schedule was not clear. Now
it is completed for all three RCU.
3. Motor Space heater isolator near motor, wiring completed.
Day 8 19‐01‐2020
4. All 3 numbers motor winding RTD connection checked. Temporary jumpers
removed.
5. Wiring between VFD & 6.6KV SWBD, cable termination schedule was mostly
many terminals were wrong. Many wires found wrongly connected. It is
corrected. Additional required signals also wired. Both end wiring completed.
6. Proper cable termination document prepared with BEC/CES
1. VSD‐24110‐ Isolator Q0 Kirk key was stuck. Mechanical adjustment done now Q0
isolator operation ok & Kirk is working ok.
2. Continuity & IR value for 6.6KV SWBD to all three VFD completed. (HV cable).
3. Continuity & IR value for 6.6KV SWBD to all three VFD completed. (HV cable).
4. IPS/FCS/Control room To VFD panel all connections removed & put tape on it as
Day 9 20‐01‐2020 other side connection is not completed.
5. VSD‐24110‐ 415VAC & 220 VAC supply energized. VFD internal testing started.
6. Panel lighting, heating, socket circuit checked.
7. Motor Space heater continuity & IR done. Motor space heater power switched
on.
8. VFD T1 transformer primary winding IR done with 5KV megger.
1. All three VFD 6.6KV power cable IR & HV test completed. 6.6KV SWBD to VFD.
VFD to Motor.
Day 10 21‐01‐2020
2. VSD‐ 24110, 24111 & 24112 internal testing in progress.
Internal test details will be submitted in the test reports.
1. VSD‐24110 & VSD‐24112 internal testing with 3PH 415VAC & 220VAC control
supply is completed. All power & control component energized & checked.
2. VSD‐24111 internal testing in progress.
Day 11 22‐01‐2020
3. Awaiting 6.6KV supply to energize the phase shift transformer with 6.6KV & do
internal final test. During this test Motor cable at VFD panel will be removed &
isolated with HV shroud. Then we are ready for solo run.
4 of 9
SITE SERVICE REPORT
Project MARMUL PUMP REPLACEMENT PROJECT
Client PDO
Vendor WEG
Material WEG MV VFD MVW3000
PO 4800012806
Report DAILY SITE SERVICE REPORT
4. VSD‐24112 ES1 earth switch mechanical adjustment done for proper operation.
During inspection found that ES1 operating rod holding mechanism broken.
Spare part requested from WEG factory.
5. Phase shift transformer & Motor digital temperature monitor controller
setting done for all three VFD.
6. VSD‐24111 motor R phase RTD not showing correct reading. Need to check at
field.
7. Motor IR, PI & winding resistance completed by BED/CES.
8. 6.6KV VFD feeder breaker mechanical issue resolved by BEC/CES.
1. VSD‐24112‐ ES1 Earth switch limit switch adjustment done.
2. VSD‐24111‐ Internal test completed.
3. Internal component functional description label printed & fixed for all three VFD
Day 12 23‐01‐2020 panel.
4. 6.6 KV SWBD to all three VFD panel signal tested with CES.
5. VFD panel test report BEC requested asap. Today evening at home will do test
reports.
1. 6.6 KV SWBD to all three VFD panel signal tested with CES & PDO witness.
Day 13 24‐01‐2020 2. PDO format test report completed & submitted.
3. WEG internal test reports completed. Reports are ready for signatures.
1. VFD date time setting done.
2. Parameter back to HMI.
Day 14 25‐01‐2020
3. Parameter back file created.
4. All parameter setting & protection setting reverified.
1. All VFD protection setting shown to PDO/BEC/CES
2. Motor RTD simulation done. Readings found ok.
3. We received 6.6KV power to VFD panel at 2.30 PM.
4. MAR‐VSD‐24112
VFD panel energized.
Motor bump test done. Rotation ok.
Motor running at 2981 RPM for one hour.
All required parameters observed & found ok.
Tomorrow we will do solo run for 4 hours.
Day 15 26‐01‐2020
5. MAR‐VSD‐24111
VFD panel energized.
Pre‐charge circuit checked ok.
Some fine tuning required in the parameter.
Tomorrow planned to do solo run
6. MAR‐VSD‐24110
VFD panel energized.
Pre‐charge circuit checked ok.
Some fine tuning required in the parameter.
5 of 9
SITE SERVICE REPORT
Project MARMUL PUMP REPLACEMENT PROJECT
Client PDO
Vendor WEG
Material WEG MV VFD MVW3000
PO 4800012806
Report DAILY SITE SERVICE REPORT
Tomorrow planned to do solo run.
1. MAR‐VSD‐24112
motor solo run started at 9.30 AM. and stopped at 3.30 PM.
VFD & Motor running normal.
Motor running at 2978 RPM.
Reading taken every 15 min.
Motor vibration reading also taken by PDO team.
2. MAR‐VSD‐24111
Motor bump test done. Rotation ok.
motor solo run started at 9.30 AM and stopped at 11.30 AM.
VFD & Motor running normal for 2 hours until 11.30 AM.
Motor running at 2978 RPM.
Reading taken every 15 min.
Motor NDE side some abnormal sound started coming.
Motor switched of at 11.30 AM.
Sound is not very noisy but as precaution we stopped the motor.
Day 16 27‐01‐2020
3. MAR‐VSD‐24110
Motor bump test done. Rotation ok.
motor solo run started at 10.00 AM
VFD running normal.
At motor NDE side observed abnormal sound.
NDE side inspection cover opened & checked. During visual inspection nothing
found.
Restarted the Motor at 11 AM. Still observed same abnormal sound.
It is suspected that cooling fan impeller is touching to fixed part.
Motor was running at 1445 RPM. Since abnormal sound we did not run it to 2978
RPM.
Motor stopped after running for 5 min.
4. It is advised to mobilize WEG motor mechanical expert to inspect & rectify the
issue.
5. All three VFDs are ok. VFD related works are completed
1. As built drawing making.
2. Test report sign off by all concern team.
Day 17 28‐01‐2020 3. Site service report preparation & sign.
4. Time sheet sign.
5. Travel‐ Marmul‐Muscat‐Dubai.
3. Tentative schedule for SOW & Task list.
6 of 9
SITE SERVICE REPORT
Project MARMUL PUMP REPLACEMENT PROJECT
Client PDO
Vendor WEG
Material WEG MV VFD MVW3000
PO 4800012806
Report DAILY SITE SERVICE REPORT
Schedule:
Tentatively 12 days required to complete attached task list activities.
Task List:
Task list attached.
4. Observations.
4.1 VSD‐24111 Pump 2‐ VFD panel phase shift transformer B3A terminal bus bar found over heated marks.
This issue is resolved (refer 7.1). During VFD testing with load, this terminal will be monitored by
thermography camera.
This VFD energized and voltage ratio found ok. Power cell connected to this winding working ok. Visual
inspection done ok.
4.2 VSD‐24111 Pump 2‐ VFD panel phase shift transformer B3A terminal To Inverter panel Power Cell V3
R phase cable found missing. Power cable is 16 mmsq 7.2KV special flexible cable. This cable is from
Column 2 to Column 3.
This issue temporarily resolved on 18th Jan. by using temporary cable. BEC gave 11KV, 35 mmsq cable.
4.3 VSD‐24111 Pump 2‐ VFD panel earth switch operating handle found missing.
5. Recommendation.
5.1 Dedicated earth cable between VFD panel & Motor frame.
5.2 Presently Incoming supply to VFD panel is 7KV. It is advised to make this voltage to 6.6KV.
5.3 VFD minimum spare parts to be kept with PDO.
6. Notes.
6.1 230V AC 2 no’s UPS supply & 3 Ph 415 supply energized by 16th Jan.
6.2 6.6KV power to VFD received on 26th Jan.
6.3 Cable termination schedule found lot of mistakes.
6.4 Few interface signals between VFD & 6.6KV SWBD decided at site for safe VFD operation.
6.5 Additional component functional description labels fitted for easy O&M.
7. Issues reported by PDO/BEC on VFD panel.
7.1 VSD‐24111 Pump 2‐ VFD panel phase shift transformer B3A terminal bus bar where flexible cable to be
terminated is found burnt (partly melted). Could have burnt during load test at factory.
At site, this B3A bus bar terminal cleaned & repaired. Bolt replaced. Winding continuity & IR checked found
ok. Informed WEG factory about this, awaiting reply.
This could have happened during load test at FAT due to loose connection. But transformer winding is ok.
During no load test we observe this 3BA terminal & found ok.
During load test also we will observe this terminal.
8. WEG to arrange below materials, document, setting to complete the project
8.1 One earth switch operating handle missing. WEG to provide.
8.2 Missing 7.2 KV , 16mmsq, 6‐meter special flexible cable for VSD‐24111. WEG to provide.
8.3 VSD‐24112 ES1 earth switch internal component found broken during inspection. WEG to provide.
7 of 9
SITE SERVICE REPORT
Project MARMUL PUMP REPLACEMENT PROJECT
Client PDO
Vendor WEG
Material WEG MV VFD MVW3000
PO 4800012806
Report DAILY SITE SERVICE REPORT
8.4 Safe Operating procedure for VFD. WEG to provide.
8.5 Operation & Maintenance manual. WEG to provide.
8.6 Final VFD setting document.
8.7 Basis for VSD protection settings shall be provided by SPX/WEG for review and clarification by
UEE1 (Head of Protection, PDO) and the same shall be reflected in protection studies.
8.8 Transient voltage dip ride‐through and fly back feature for extended duration voltage dips have
to be enabled and set in order to minimize impact on process during power system faults.
9. PDO to clarify below.
9.1 Control room interface VFD not ready.
9.2 Speed reference for Local & Remote operation is from Control room. PDO to confirm in both mode VFD
will receive one 4‐20 mA analog input.
9.3 VFD to control room RS485 Modbus communication. Slave ID required. List of Modbus I/O signal.
9.4 RCU has 3 position switch. Off‐Auto‐Start Pulse.
In this project only OFF signal is used.
Presently from field there is no emergency stop push button.
Off button can not be renamed as Emergency stop.
Dedicated emergency stop PB to be installed near motor with 2 NC contact.
9.5 Basis for VSD protection settings shall be provided by SPX/WEG for review and clarification by
UEE1 (Head of Protection, PDO) and the same shall be reflected in protection studies.
Need more clarification on this.
Protection setting document already provided by WEG.
9.6 Transient voltage dip ride‐through and fly back feature for extended duration voltage dips
have to be enabled and set in order to minimize impact on process during power system
faults.
PDO to specify duration of voltage dip value & time in order to check & evaluate VFD setting.
9.7 There is no dedicated earth cable between VFD panel to Motor frame.
As per WEG VFD installation manual there should be dedicated 35 mmsq earth cable between
VFD panel to motor.
9.10 MAR‐VSD‐24110 & 24111 both motors have some abnormal noise during solo run.
PDO/BEC to arrange WEG mechanical motor expert to resolve this issue.
9.11 PDO to sign solo run & VFD panel test report.
10. BEC to follow up below works.
10.1 Seal the VFD panel bottom holes completely.
10.2 RTD simulation test for all three motors from field. From VFD panel terminal to temperature
monitor already done by WEG.
10.3 Field RPM meter calibration.
10.4 Field ammeter to be replaced with proper range.
10.5 Labels for field Switches. E.g. RCU, Motor space heater isolator etc.
10.6 Completion of mechanical works to make load run test.
8 of 9
SITE SERVICE REPORT
Project MARMUL PUMP REPLACEMENT PROJECT
Client PDO
Vendor WEG
Material WEG MV VFD MVW3000
PO 4800012806
Report DAILY SITE SERVICE REPORT
10.7 BEC to send VFD panel signed test report scan copy to WEG asap.
We need to send this report to WEG factory for review & for their comments/advice.
10.8 BEC to send Motor photos. Motor Name plate, RCU, Motor space heater isolator, JB.
Motor NDE side photo.
10.9 Latest cable termination schedule.
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