Method Statement for: Motors

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for MOTORS Issue Date:

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DOCUMENT REVIEW AND COVER SHEET Company:

Engineering Contractor:

Review:

Construction Contractor:

PROJECT

Gazprom Neftehim Salavat Acrylic Acid / Acrylates Plant (RSAE) Project Bashkortostan, Russian Federation

CONTRACT NO

88621 - December, 2012

DOCUMENT TITLE DOCUMENT NUMBER DOCUMENT Status DESCRIPTION Status

METHOD STATEMENT for MOTORS RSAE

- PRC

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Revieved Engineer:

NAME

Remarks or Comments:

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Quality Control Procedure Code Description

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APPROVED WITHOUT COMMENT REVISE AND RESUBMIT. WORK MAY PROCEED SUBJECT TO INCORPORATON OF CHANGES INDICATED. REJECTED. TO BE REVISED B: RESUBMITTED. WORK MAY NOT PROCEED INFORMATION ONLY. REVIEW NOT REQUIRED. WORK MAY PROCEED CANCELLED/SUPERSEDED SIGN

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Issued for Approval

Rev.

Amendment

Prepared

Checked

Approved

Date

Company:

Engineering Contractor:

Construction Contractor:

Project Title:

Gazprom Neftehim Salavat Acrylic Acid / Acrylates Plant (RSAE) Project Bashkortostan, Russian Federation

Document Title:

METHOD STATEMENT FOR MOTORS



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REVISION SHEET Revisio n A1

Description of changes First Issued For approval

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Contents 1. PURPOSE 5 2. SCOPE………………………………………….…………………………………………….....5 3. DEFINITIONS

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4. RESPONSIBILITIES……………………………………………………………………...……6 5. PREREQUISITES and PRECAUTIONS……………………………………………..…..……6 6. PROCEDURES………………………………………………………………………………...8 7. ACCEPTANCE CRITERIA……………………………………………………………..….…12 8. ATTACHMENTS…....…………………………………………………………………...……13



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1. Purpose This procedure provides a safe, standardized approach for the initial inspection, checkout, testing, and data documentation of electric motors used to drive rotating equipment. 2. Scope This procedure is applicable to the RSAE project Site and covers all motors. It applies to AC MV and AC LV motor used to drive rotating mechanical equipment. Motors used as operators for valves, gates, dampers, etc. are not within the scope of this procedure. This procedure shall be implemented during initial uncoupled/unloaded operation of applicable equipment, as well as during the initial coupled/loaded operation. However, it may be used at any time during equipment operation. 3. Definitions      

Project : Gazprom Neftehim Salavat Acrylic / Acid Plant Company : Gazprom Neftehim Salavat Construction : Renaissance Construction (RC) Supplier (Manufacturer/Vendor) : The supplier (Manufacturer/Vendor) is the party that manufacturers or supplies equipment and services to perform the duties specified by the Company or Contractor. The word SHALL indicate a requirement. The word SHOULD indicate recommendation.

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Drive End (DE) - The end of the motor from which the shaft protrudes and is coupled to the driven equipment. It may also be referred to as the inboard (IB) end of the motor.

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Non Drive End (NDE) - The end of the motor that is opposite the DE. This end of the motor usually has the motor’s cooling fan attached. It may also be referred to as the opposite drive end (ODE) or outboard (OB) end of the motor.

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Bump - To start and immediately stop a motor from a Local Control Switch or temporary remote signal instead of DCS signal to verify direction of rotation.

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Rotation - The rotation of a motor as viewed from behind the NDE, standing with line of sight in-line with the rotor, looking toward the drive shaft of the driven equipment.

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Magnetic Center - That position of Sleeve bearing type motor rotor where the magnetic forces acting on the rotor are in balance during operation. In large motors during initial run-in, the magnetic center is marked to allow positioning of the rotor at the magnetic center for coupling alignment. Placement of the rotor at the magnetic center assures that no thrust from the motor is transmitted to the driven equipment via the coupling.



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 Motor Doweling - A practice on some large motors where the motor base is drilled and dowels inserted to prevent movement of the motor. This is usually done to permanently fix the final alignment position of the motor. In some cases the driven equipment may also be doweled in place. 4.

Responsibilities

4.1

Test Program Manager Has overall responsibility for test program and shall act as Test Program Manager.

4.2 Test Engineer Has responsibility for detailed checkout and testing of electric motors and shall act as Test Engineer. Coordinates with discipline engineers, operations, and test performers to accomplish testing and completes the Motor Data Record. The Test Engineer performing this procedure shall ultimately be responsible for all evolutions. Correct rotation of the Motor (in relation to the driven equipment) must be verified by the Mechanical Commissioning Engineer. 4.3

Health, Safety and Environmental (HSE) Representative Participates in and provides input to Safety Task Analysis Risk Reduction Talk (START)/Job Hazard Analysis (JHA). Provides HSE coverage for test activities and walk downs.

5. PREREQUISITES AND PRECAUTIONS 5.1

Prerequisites 5.1.2 Verify that test equipment used for recording data are calibrated within their calibration interval and document on the Motor Data Record. Temporary barricade not to access the unauthorized person shall be provided around inspected motor before motor operation 5.1.3 Verify that the equipment is correct (per data sheets, specifications, etc.) and installed in accordance with project design documents and vendor manuals/drawings. Also verify that the system installation is complete to the extent necessary to properly support equipment operation. Review system/component punch list. 5.1.4 Review the vendor’s instruction manual(s) for special precautions or limitations specific to the equipment/system’s components. Note and observe the vendor's precautions and limits, such as number of starts, run-in duration, vibration, load, etc.



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5.1.5 Verify that equipment lubrication is in accordance with the vendor's specifications, and either a lubrication tag is attached or other documentation is verified. 5.1.6 Verify that protection systems, instrumentation, controls, and alarms associated with the equipment under test are tested, calibrated, functional, and documented to the extent necessary to support testing. 5.1.7 Verify that the motor bearing lubrication and cooling system, if any, is available for operation. If applicable, also verify that auxiliary cooling fans have been checked out and are available. 5.1.8 All LV and all MV Motors shall be uncoupled prior to initial start and run-in. 5.1.9 Verify that the motor supply breaker/switchgear has been functionally tested to permit motor operation. 5.1.10 Ensure that motor filters are installed if applicable. Replace filters as required. 5.2 Precautions 5.2.1 Areas under test must be clean and free of loose debris and only authorized personnel are permitted in test areas. 5.2.2 Systems (complete or partial) or equipment under initial test where high energy will be introduced for the first time must be physically walked down to ensure unauthorized personnel are removed from test areas. As required, personnel may be stationed at designated locations to keep test areas free of unauthorized personnel. Emergency egress routes must be identified and verified clear of obstructions. 5.2.3 Equipment Lock out / Tag out (LOTO) requirements in support of this activity must be implemented 5.2.4 A pre-test briefing incorporating STARRT/JHA must be conducted. Discuss test performance and expected results with involved personnel. Personal Protection Equipment (PPE) identified in the STARRT/JHA is required to be worn during performance of this test. 5.2.5 Special attention must be provided for protection of personnel and equipment. Ensure precautions such as barriers, flagging, danger signs, horns, area restrictions, etc., are used to protect personnel and equipment. NOTE: Special attention should be paid to areas parallel to rotating equipment shafts. These zones are especially susceptible to debris launched tangentially from rotating equipment during a failure.



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5.2.6 Immediately terminate testing if any unusual noises, smoke or anomalies occur, or if design limits that may compromise the safety of personnel or equipment are exceeded. Immediately notify the Lead Electrical Commissioning Engineer and the site HSE representative (if applicable) of such occurrences. 5.2.7 Assure adequate access is provided to all required areas during the test. Where permanent access is not provided, scaffolding or a man lift must be provided in accordance with job site procedures. 5.2.8 Establish appropriate level of communication between test and HSE personnel. 5.2.9 Loose fitting clothing or long hair shall be properly secured to prevent entanglement when working around moving equipment. 5.2.10 Rotating parts, such as couplings, pulleys, external fans, and unused shaft extensions, should have permanent guards installed to prevent accidental contact with hands or clothing. This is particularly important where the parts have surface irregularities such as keys, keyways or setscrews. 5.2.11 Loose parts of the coupling that cannot be removed for the motor uncoupled run-in shall be tied off or affixed in such a way that they shall not contact the motor shaft or any other rotating part. 5.2.12 Equipment must not be operated unless its supervisory and protective devices are calibrated, tested, and functional. No protective devices shall be de-rated or bypassed unless temporary protection is provided. 6. Procedure NOTE: The vendor’s instruction manual and vendor requirement takes precedence over this procedure in the event of conflicts. Detailed equipment operation shall be according to vendor manuals. 6.1 General 6.1.1 This test shall be performed concurrently with the Equipment Vibration Testing Procedure. The Test Engineer will coordinate all activities as necessary. 6.1.2 Motor run-in time shall be as specified until bearing temperatures and winding temperatures (as applicable) stabilize. A temperature is normally considered stable when three successive readings taken at 10-minute intervals do not vary by more than ±5 percent. A 4 hours run-in time shall be considered adequate for all motors with Motor rated voltage: 380V AC.

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6.1.3 During initial run-in, record those equipment parameters that have an accessible indicator. Typical parameters that establish the motor's characteristics include bearing temperatures, winding temperatures, lubrication flows and temperatures, etc. The data should have a common time basis and be recorded at a specified interval. The following are several acceptable recording methods: Manual recording of local indicators/digital meter on MCC in substation



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6.1.4 Use the Motor Data Record, to document test results and attach charts, graphs, data printouts, etc. Data collection can be stopped when monitored parameters have stabilized.

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6.1.5 During the coupled run-in of variable or multi-speed equipment data should be taken at: Operational speed (60Hz) NOTE: On variable speed equipment, particular attention should be exercised to avoid operation at, or near, the equipment critical speed. 6.1.6 Temporary alterations installed during testing shall be recorded on Motor Data Record. Temporary alterations that are to remain following completion of testing shall be logged according to the requirements of the Control of Temporary Modifications Procedure.

6.2 Inspection 6.2.1 Ensure that the motor is clean and dry. The motor and Tag plate shall be legible. End bells, covers, filters, and accessories shall be firmly attached. 6.2.2 Record motor nameplate data on the Motor Data Record. 6.2.3 Verify that the voltage, phasing and the frequency of the motor’s power supply agree with those on the motor nameplate and the appropriate drawings. 6.2.4 Verify that motor terminations are properly made up. 6.2.5 Verify that the motor is properly grounded in accordance with the project grounding notes, symbols, and details. Standard drawing (3935 E206-00100) 6.2.6 Inspect collector rings and brushes. The collector rings shall be clean and free of any mechanical damage. The brushes shall make good contact with the slip rings and the brushes shall slide smoothly in their holders. 6.2.7 Verify that the motor protection circuits have been set. Record the initial settings in the comment section of the Motor Data Record, Exhibit 1.6.2.8 Verify that all protective relays have been calibrated and functionally tested. 6.2.9 Inspect cable gland connections for instrument and power cables ensuring that bushings are installed, tightly and cable protection cover (If necessary) are installed.



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6.3 Pre-Run Tests 6.3.1 The insulation of the motor windings and power cable should be meggered. 6.3.2 The winding resistance and the applied voltage shall be measured phase to earth. 6.3.3 Support systems, such as lube oil or cooling water, shall be placed into operation. 6.3.4 The motor shaft shall be manually rotated (if possible) to ensure that the rotor moves freely, without rubbing. 6.3.5 Phase rotation may be initially checked using a motor phase rotation meter for any motor. However, an initial check by actual motor rotation (bump) is mandatory for motors because driven equipment that might be damaged by reverse rotation: a. Supply the Lockout/Tagout on breaker of power supply. b. Connect the leads of the phase rotation meter to the motor terminals at the motor terminal box or feeder (load) terminals for the motor at the starter or switchgear. c. Slowly rotate the motor shaft (rotor) in the proper direction of rotation for the driven equipment and verify that the phase sequence on the meter matches the phase sequence of the line (supply) connections. d. If the phase sequence indicated on the meter does not match the design (line) phase sequence, interchange the motor leads of two phases at motor internal wire. NOTE: If leads need to be swapped all labels, tags, markings, etc. need to be revised to match issued drawings. e. Recheck the phase sequence of the motor winding using steps b. and c. above and record the sequence on the Motor Data Record. f. Remove the Lock out / Tag out. 6.3.6 For a motor supplied from a load center or switchgear bus, place the breaker in the operating position (racked-in). For a motor equipped with a starter and supplied from a motor control center and/or distribution panel, place the breaker in the closed position. Verify that the motor space heaters, if supplied, are energized and note their operation in the comment section of the Motor Data Record, Exhibit 1. NOTE: Space heaters must energized for the minimum amount of time required by the manufacturer prior to attempting a motor start. If no guidelines are given the heater should be energized for 8 hours prior to attempting the start. 6.3.7 After the preliminary rotation verification all motors must be “bumped” for a final verification of proper rotation. 6.3.8 Ensure that the safety switch adjacent to the motor is function checked before starting motor.



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6.4 Motor Start and Run 6.4.1 If, at any time during the implementation of this procedure, any parameter or condition is out of acceptable limits and cannot be readily corrected, the evolution in progress shall be terminated and the system or component placed in a safe configuration. Motor solo run shall be done all MV motor and installed outdoor LV motor. But some motors are not dismantle mechanical coupling. Their motors shall not be applied motor solo run test. 6.4.2 Clamp an ammeter on one of the motor leads at the breaker and set it to record the maximum current draw. Alternatively if the motor manager or protection relay can record starting current, this should be used instead of clamp on ammeter. Start the motor, locally if possible. Record the starting current on the Motor Data Record, Exhibit 1. 6.4.3 As the motor comes up to speed, monitor it for smoothness of operation and for any unusual or unexpected noises. 6.4.4 with the motor running: take running current on all phases, phase to phase voltages, and motor rpm measurements and verify that the motor space heater is deenergized. Record readings on the Motor Data Record. 6.4.5 If applicable tune variable speed drive to the system attributes and verify frequency settings. 6.4.6 Check that the motor bearings are being properly lubricated (e.g. bearing oil rings are rotating, no excessive foaming, levels are correct). Monitor bearing temperatures as the motor is run in. When they have stabilized, record the measurement. 6.4.7 Monitor motor winding temperatures, if available. When they have stabilized, record measurements on the Motor Data Record, in the comment section. 6.4.8 Take vibration data as required. Refer to Equipment Vibration Testing Procedure. Vibration readings that exceed limits may result in motor damage, and operation may have to be secured. 6.4.9 Verify temperature, current, and vibration readings against any local or remote indications. 6.4.10 Verify magnetic centre position indication, if applicable. Apply new mark after vendor's confirmation if necessary. 6.4.11 When the vendor’s run-in criteria have been met or the temperatures are stable secure the motor and monitor for smooth coast down. 6.4.12 Repeat the activities of the uncoupled motor start and run-in when the motor is coupled. Record the data on the Motor Data Record. 6.4.13 After final alignment and motor and driven equipment run-in, the motor may be doweled in position as required by the vendor. 6.4.14 Ensure that motor stops when local control stop button is put in off position and cannot be started again from.

6.5. Restoration



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6.5.1 Verify that temporary alterations made during the performance of this test have been restored or controlled according to Control of To be submitted in case restoration is required. 6.5.2 Verify that temporary test equipment has been removed, and all system connections and permanent equipment are replaced and secured. Ensure terminal box cover is tight and has appropriate gasket installed. 6.5.3 Verify that equipment and system(s) affected by this procedure are restored to conditions as specified by the person responsible for the system(s). 6.5.4 Verify that applicable previous data records have been completed. 7. Acceptance Criteria All equipment operating parameters including vibration, currents, voltages, resistances, and temperatures shall be within project design and vendor requirements and tolerances. The motor operation shall be generally smooth. Refer to the vendor’s manual. Insulation Resistance (Megger) Testing are within project design and vendor requirements. In some cases the motor may be run for an extended period of time to dry out the motor and allow the insulation resistance to increase over time. 8. Attachments A—Motor Run Testing Process Map B—Motor Run Testing Process Map (cont’d.)



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Attachment A Test Engineer

Verify motor protection and control circuits have been checked out. Install Lockout & Tagout on breaker for power supply

NO

Hand rotate shaft and check for rubbing Megger per 530-U07-00308 Insulation Resistance (Megger) Testing Measure winding resistance and applied voltage Phase to Ground

Verify phase rotation with phase rotation meter

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Motor Run Testing Process Map

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Construction

Inspect for correct insulation, lubrication, cleanness, correct, voltage, phasing & frequency etc.

Is motor 250V DC or 380V AC of more than 50HP/37,5kW? (All Motors”

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Uncouple motor from driven equipment. If possible

Engineering



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Attachment B From Page 1

Place support system in service

Close breaker/rack- in switchgear Remove Install Lockout & Tag out on breaker

Is rotation Correct?

NO

Swap leads to correct rotation and update markings

Start and run motor. Taking data and monitoring operation

Verify heater de energizes if applicable

Run-in motor unit bearing and winding temperatures are stable and all other vendor run-in criteria are met

Secure motor and monitor for smooth coast down

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Motor Run Testing Process Map (cont’d.)

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Method Statement for: Motors

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