AA SPEC 538011

MEDIUM VOLTAGE INDUCTION MOTORS SPECIFICATION

VERSION 1 14 JANUARY 2013 COPYRIGHT

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MEDIUM VOLTAGE INDUCTION MOTORS

1 2 3 4

Scope Technical Requirements to be Specified by the Engineer Definitions & Abbreviations Requirements 4.1 4.2 4.3 4.4 4.5 4.6 Safety Design Material Properties Mechanical Properties Electrical Properties Corrosion Protection

3 3 3 4 4 4 20 20 21 21 21 21 21 21 21 23 23 23
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5 6

Quality Assurance Provisions Test and Inspection Methods 6.1 6.2 6.3 6.4 Chemical Tests Mechanical Tests Electrical Tests NDE

Marking and Packing 7.1 Marking

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VERSION 1 14 JANUARY 2013 COPYRIGHT

7.2

Packing

23 24 25

Appendix A: Referenced documents Appendix B: Record of Amendments

Appendix C: Data Sheet To Be Completed By The Engineer And The Contractor For Each Motor Type 26

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AA SPEC 538011

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VERSION 1 14 JANUARY 2013 COPYRIGHT

SCOPE
This specification details the requirements for fixed speed, three-phase, alternating-current, air or water cooled squirrel cage and wound rotor (slip ring) induction motors for voltages from 3 300 to 13 800 V between lines and at a frequency of 50 Hz or 60 Hz. This specification does not cover synchronous motors or special motors for variable speed drives.

TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER

The following information shall be specified in all tenders, contracts or orders: a) b) Title, reference number and issue number of this specification. The completed data sheet. (Contractors supplying motors to this specification are to ensure that they receive completed data sheets indicating the Engineers requirements)

DEFINITIONS & ABBREVIATIONS

For the purposes of this specification the following definitions shall apply: ETD ECP : : Embedded Temperature Detector End Corona Protection: The final layer applied to the stator coil in the vicinity of the slot exits which is designed to make electrical contact with the OCP and has a voltage dependent resistivity so that electrical stress concentration on the surface of the coil is relieved to prevent potentially dangerous partial discharge in service. The length of the ECP is dependent on the voltage, altitude and/or the contractor's design standards. Sometimes referred to as stress grading IEC NEMA OCP : : : International Electrotechnical Commission National Electrical Manufacturers Association Slot Corona Protection / Corona Shield: The conductive final layer which constitutes the surface of the stator coil in the slot portion and extending approximately to the end of the press fingers, which is designed to make electrical contact with the core at regular positions along the slot and which has a resistivity that is: a. b. Independent of voltage stress, Low enough that the surface of the coil is maintained at a voltage sufficiently close to earth potential so as to prevent potentially dangerous partial discharge at the same location will occur between the coil surface and core, High enough that it will not result in increased core losses due to short circuiting of the core lamination plates.
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b)

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AA SPEC 538011

MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

PD Un Ueff

: : :

Partial discharge Rated line-to-line voltage Effective line-to-line nominal voltage, at sea level, of the rated line-toline voltage at design altitude. Vacuum Pressure Impregnation

VPI

The following terms are defined in the General Conditions of Contract: a) Anglo American, Approved, Company, Contractor, Engineer

4
4.1

REQUIREMENTS
Safety
All equipment and services shall comply with the requirements of the relevant national safety laws and regulations (for example, in South Africa this is the Occupational Health and Safety Act and the Mines and Works Act), Anglo American Fatal Risk Standards, the Mine Engineering Codes of Practice and the Mine Standard Procedures.

4.2
4.2.1

Design
General Unless otherwise specified in this document, motors manufactured to this specification shall comply with the requirements of the latest issues of all applicable parts of all parts of the standards listed in Appendix A.

4.2.2

Duty and Rating Motor shall be manufactured for continuous running duty type S1 with a rating class for continuous duty, unless otherwise specified in the data sheet. The rated output of the motors shall be given in the data sheet.

4.2.3

Site operating conditions The site operating conditions are specified in Appendix C

4.2.4

Electrical operating conditions The electrical operating conditions are specified in Appendix C The motors shall be suitable for operation and starting on a three-phase voltage supply system having a harmonic voltage factor (HVF) not exceeding 0,03 as for design N motors as defined in IEC 60034-12 Rotating electrical machines Part 12: Starting performance of single-speed three-phase cage induction motors

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AA SPEC 538011

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VERSION 1 14 JANUARY 2013 COPYRIGHT

4.2.5

Electrical Grounding The stator windings shall have the same insulation to ground at both line and neutral ends. The motors are to be suitable for use on effectively earthed systems. The system will be either solidly earthed or limited by a neutral grounding compensator resistor or resistor only, as specified in Appendix C.

4.2.6

Thermal Performance As specified in the data sheet, the motor shall have either a limited temperature rise or a service factor as follows: a) Temperature Rise The temperature rise shall not exceed Class B minus 10 C measured by winding resistance when tested at nominal conditions in accordance with IEC 60034-2-1 Rotating electrical machines Part 2-1: Standard methods for determining losses and efficiency from tests (excluding machines for traction vehicles) and IEC 60034-2-2 Rotating electrical machines Part 2-2: Specific methods for determining separate losses of large machines from tests - Supplement to IEC 60034-2-1 and corrected for the site altitude above sea level (as specified in the data sheet). b) Service Factor The motor shall have a service factor of 1,15 and the insulation temperature rise shall be as stipulated in NEMA MG1 Motors and Generators for class B when tested at nominal conditions, corrected for site altitude (as specified in the data sheet). The Contractor shall record in the data sheet the maximum temperature rise when operating at any point in Zone A or Zone B as defined in IEC 60034-1 Rotating electrical machines. Part 1: Rating and performance.

4.2.7

Efficiency High efficiency motors are preferred. The adjudication shall be based on a capitalisation of losses according to the following formula:

Where ) )

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AA SPEC 538011

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VERSION 1 14 JANUARY 2013 COPYRIGHT

Where Symbol PNL hNL CE CMD P L hL i n Units kW hours $/kWh $/kWh/mont h kW hours per unit Definition Guaranteed no load losses No of hours per year that the motor will be operated at no load Cost of energy per hour Cost of maximum demand per month Guaranteed losses at the duty point load No of hours per year that the motor will be operated at the duty point load Interest rate Number of years over which losses will be capitalised

Where energy is charged at different rates at different periods (for example, summer and winter), the losses will be calculated accordingly. Where bidirectional motors, which are preferred, have a significant reduction in efficiency compared to a unidirectional option, the Contractor shall indicate both efficiencies in the data sheet. 4.2.8 Driven Load Full details of the driven load shall be given in the data sheet. The Contractor when requested shall liaise with the supplier of the driven equipment to ensure that the motor is suitable for the duty. Any special requirements that the Contractor may have found necessary for the particular drive from previous experience shall be brought to the attention of the Engineer. 4.2.9 Vibration

4.2.9.1 IEC Standards Where the engineer selects, in Appendix C, vibration to be to IEC standards, the unfiltered vibration limit for 2 pole machines shall be 1.8 mm / second rms when mounted rigidly in the contractors works according to IEC 60034-14 Rotating electrical machines Part 14: Mechanical vibration of certain machines with shaft heights 56 mm and higher Measurement, evaluation and limits of vibration severity. For machines of 4 pole and higher, the vibration limits shall be to grade B in IEC 60034-14. 4.2.9.2 NEMA Standards Where the engineer selects, in Appendix C, vibration to be to NEMA standards, the unfiltered vibration limit for 2 pole machines shall be Limit 0,15 as for Standard Industrial motors. For machines of 4 pole and higher, the unfiltered vibration limit shall Limit 0,08 as for Medium Large motors with Special Requirements.

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4.2.10

Starting Design The motors shall be capable of starting and accelerating the driven load specified in the data sheet at 80% of the rated supply voltage at the terminals of the motor. The direct on line starting current at nominal voltage shall not exceed six times the motor rated full load current on cage motors and the motors shall be suitable for direct on line starting whether reduced voltage starting is used or not. The run up time of the motor and load when operating at 100% and 80% of rated supply voltage shall be stated by the Contractor in the data sheet. The number of successive starts (coasting to rest between starts) from cold and hot shall be specified in the data sheet but shall not be less than three successive starts from cold (i.e. the motor at ambient temperature) and two successive starts from hot (i.e. the motor at normal operating temperature). The contractor shall stipulate the cooling period before another start attempt is permitted. The maximum stator and rotor temperature rises that would occur during this starting duty cycle shall be calculated by the Contractor and stated in the data sheet. The contractor shall stipulate the time duration that the motor can remain stalled with full voltage applied, with the motor hot and cold before the stall condition, without it resulting in damage to the motor rotor or stator. The Contractor shall also state the maximum number of starts expected for the life of the machine.

4.2.11

Data to be specified and guaranteed by the Contractor The Contractor shall complete the data sheet (Appendix C) and the certificate of compliance (Appendix D). The data quoted by the contractor in Appendix C for power factor, temperature rise, no - load losses and losses at the duty point load shall be guaranteed.

4.2.12

Critical speed The motor critical speed must be well clear of the motor operating speed and preferably greater than 20% above the normal operating speed. Where this is not possible a critical speed less than 70% of normal operating speed will be permitted. The Contractor shall state the motor calculated critical speed in the data sheet.

4.2.13

Active material The dimensions of the rotor active core material, without air ducts etc, are to be given by the Contractor in the data sheet in the form of D, L, D2L and ratio L/D, where D is the rotor diameter in metres and L the active core length in metres. Motors having a larger diameter D and shorter length L are preferred.

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AA SPEC 538011

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VERSION 1 14 JANUARY 2013 COPYRIGHT

4.2.14

Enclosures All parts of the motors shall be to gauge and be interchangeable between like machines. The motor enclosure protection and cooling form shall be as specified in the data sheet. If there are any restrictions on dimensions for transport underground, mounting on plant or for interchangeability with existing motors, the details shall be given in the data sheet. If a motor is required to be interchangeable with existing motors it is to be totally interchangeable, physically, mechanically and electrically so that no modifications to cable terminations, water or oil circuits are required when the motors are interchanged.

4.2.15

Cooling The air or water cooling systems and the heat exchanger design shall be approved by the Engineer. If a separate electrically driven cooling fan is used for the secondary circuit on a CACA system (IC5A1A6 or IC6A1A6), the system shall be approved by the Engineer. The energy consumption of the external fans shall be included in the total losses for efficiency figure. Where heat exchanger tubes are provided, such as in "CACA" machines, provision shall be made for easy cleaning of such tubes. Construction detail of fan cowlings, ducting and the related components shall be such that access to both ends of the respective cooling tubes is possible, for inspection and cleaning purposes. Water coolers shall be designed for counter current flow and all material in contact with the water shall be stainless steel type 304 or other material approved by the Engineer. The Engineer shall provide a detailed water analysis to enable the motor manufacturer to select the correct materials. The flow rates and pressure withstand capability of the water cooler shall be given by the Contractor in the data sheet. Where a common water cooling system is used for the driven load (for example a compressor) and the motor, the motor Contractor shall liaise with the Contractor of the driven load to ensure a compatible cooling water system. Water coolers shall have means of detecting water leaks and protecting the windings from any leaks that may occur. Water cooling systems shall be tested at not less than 1.5 times the maximum operating pressure of the system. The coolers shall be so arranged as to permit their easy removal as a unit from the motor with the minimum of disturbance to the cooling water pipe work. Suitable drainage pipes shall be provided to permit emptying of the coolers prior to their removal. Cooling water quality shall be as defined by the project specification.

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4.2.16

Shaft The shaft shall be adequately sized for the duty and be designed and manufactured in accordance with the requirements of Anglo American specification AA 538032 Shafts for electric AC induction machines with frame sizes 355 and larger. Unused shaft extensions shall be enclosed in detachable, robust metal covers.

4.2.17

Coupling The supply, machining and fitting of the coupling shall be as given in the data sheet. Where a coupling is supplied or fitted by the Contractor it shall be separately balanced and then fitted to the motor.

4.2.18

Shaft mounted cooling air fans The motor and the shaft mounted cooling air fans shall be suitable for bi-directional rotation. In the event that this reduces the efficiency of the motor by more than 0.25% or requires extra silencers to achieve the noise level limits, the Contractor shall offer as an alternative unidirectional motors and fans. In the case of unidirectional motors the bearings shall be suitable for bi-directional rotation so that by changing the fans the direction of rotation may be altered.

4.2.19

Air gap The stator and rotor shall be designed, manufactured and assembled so as to produce a uniform air gap. The air gap shall be as large as possible consistent with achieving a satisfactory power factor. The minimum air gap acceptable to the Engineer will vary from motor to motor, but shall be considered in relationship to the machine size and speed, enclosure material, viz. mild steel or cast iron, and the type of bearings. The motor shall have facilities to measure the airgap at three points 120 degrees apart on each end of the motor.

4.2.20

Bearings The Engineer's preferred bearing arrangement viz. either grease lubricated ball and roller bearings, oil lubricated end shield mounted sleeve bearings or oil lubricated pedestal mounted sleeve bearings shall be indicated in the data sheet. Any alternative bearings systems proposed by the Contractor will need to be approved by the Engineer. No axial thrust from the driven load shall be transmitted to the motor bearings but the motor bearings shall be suitable for absorbing the thrust of the motor rotor floating uncoupled. Both the drive end and non-drive end bearings shall be insulated. The drive end bearing shall be fitted with an earth strap, which can be easily removed for testing, to connect the insulated bearing to the frame. On all 2 pole motors from 500 kW and above and on all lower speed machines from 1 000 kW and above, the drive end shaft shall be grounded to the motor frame by a ground brush. The Contractor shall indicate the maximum allowable bearing temperature in the data sheet.
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AA SPEC 538011

MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

4.2.20.1 Oil lubricated sleeve bearings Where the engineer specifies antifriction bearings, these shall comply with this section. The bearing assembly shall comprise a spherically seated horizontally split sleeve bearing, an oil reservoir and oil rings to transfer the oil from the reservoir to the top of the journal. The reservoir shall be adequately sized to enable the bearing to be naturally air-cooled and to maintain the bearing temperature within the permissible temperature of the bearing with an ambient air temperature of 40 C. The white metal shells shall be doweled for proper location of top half to bottom half and the top half shall be located by a pin in the top casing. The white metal bearing shells shall be suitable for reconditioning in accordance with Anglo American Specification AA 232001 Reconditioning of white metal bearings The bearings shall be either end shield mounted or have pedestal bearings as selected by the Engineer in the data sheet. The bearing assembly shall be for a naturally air cooled system but it shall be supplied complete with all the pipe fittings (with insulation) etc. necessary to add on site at a later stage if it is found necessary a regulated circulating oil system without replacing or altering the bearing unit. The bearing oils shall be in accordance with Anglo American Specification AA 166000 Lubricants general requirements. The oil reservoir shall be fitted with a sight glass on which the bearing oil level for both the motor stationary and the motor running is indicated. The regulated circulating oil system shall feed oil to the bearing and have an oil outlet arranged so as to keep the oil in the bearing at the correct level. The design shall be such that the forced lubrication shall be able to operate with the oil rings remaining and should a failure of the oil ring occur whilst the circulating oil system is used; the bearing will be satisfactorily lubricated without requiring the oil flow to be increased. If the allowable temperature rise of the bearing cannot be achieved with a naturally air cooled system then a circulating oil lubrication system incorporating an external water or air heat exchanger shall be provided. Alternatively, a water jacket cooled bearing system shall be used. The system offered shall maintain the temperature of the white metal below 40 C. The system shall be approved by the Engineer. The bearing shall be fitted with an inspection aperture through which the oil ring and forced lubrication oil feed may be observed whilst the motor is running. Attention shall be paid to sealing the bearing from oil leaks and preventing oil mist and vapour from being drawn into the windings by the ventilation system.

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The bearings shall be fitted with spring loaded 100 ohm platinum resistance temperature detectors (RTDs). These shall be fitted into holes drilled into the bearing shells so that the tip of the probe is as close to the load line and to the white metal as is practicable. Both drive end and non-drive end bearings shall be insulated and the type of insulation material and the method of insulating the bearing shall be approved. The drive end bearing shall be fitted with an earth strap, which can be easily removed for testing, connecting the insulated bearing to the frame. Where the motor has oil lubricated sleeve bearings the motor shaft shall be marked on the shaft extension end with a mark and an indicator shall be fitted to the bearing housing to indicate the correct neutral axis running position of the rotor. The neutral axis shall be in the centre of the end float between the bearing thrust shoulders of the bearings. In the case of unidirectional motors the bearings shall be suitable for bi-directional rotation so that by changing the fans the direction of rotation may be altered. 4.2.20.2 Grease lubricated anti-friction bearings Where the engineer specifies antifriction bearings, these shall comply with this section. Bearings shall be grease lubricated anti-friction ball or roller type bearings having C3 internal clearance designation and a brass cage. Polyamide cages shall not be permitted. Only approved Manufacturers of bearings, as required by the Contract or Order shall be used. Grease relief systems, which allow the bearing to be greased through grease nipples whilst the motor is running or stationary and in which the excess old grease is automatically expelled to the outside of the motor when the motor is running, shall be provided. The bearing system preferred by the Engineer and that offered by the Contractor shall be given in the data sheet. Where grease relief systems are provided there shall be a means of removing the expelled grease from the bearing without dismantling any part of the motor and whilst the motor is operating. Grease used shall be general purpose type No. 2 or No. 3 consistency having a Lithium complex base with an extreme pressure additive or as advised by the Engineer. The Contractor shall indicate in the data sheet the expected grease life. The bearings shall have grease reservoirs that will allow more than 4 000 hours operation without re-greasing. The B10 calculated bearing life shall be given in the data sheet and the calculations shall be submitted to the Engineer if required. The calculated bearing life shall be in excess of 100 000 hours for direct coupled driven loads.

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AA SPEC 538011

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VERSION 1 14 JANUARY 2013 COPYRIGHT

The bearings shall be fitted with spring loaded 100 ohm platinum resistance temperature detectors (RTDs). These shall be fitted into holes drilled into the bearing shells so that the tip of the probe is touching the outer race. The ball and roller bearing housings shall also be supplied with a spot face with an M8 tapped blind hole suitable for the installation of SPM shock pulse transmitter units.\ An automatic re-greasing system shall be supplied where specified by the engineer. 4.2.21 Sliprings and Brush gear

4.2.21.1 Brush lifting and slip ring short circuiting gear Where slip rings and brush gear are fitted, the preference is for brush lifting and short circuiting gear. On machines below 1 000 kW the brush gear lifting operation may be manual. On larger machines, brush gear lifting shall be motorised with manual override. Such gear shall be fitted with auxiliary interlock switches operating in the fully "in" and fully "out" position to be used for interlocking with the main motors starter to prevent starting with the brush gear in the short circuited position and for the protection circuit to ensure that the slip rings are shorted and the brushes lifted within a certain time after starting. All bushes and pins, forming part of the mechanism, should be protected against corrosion where practical. Machines without motorised brush lifting and short-circuiting gear, shall have brushes rated for continuous duty. The actual brush configuration shall be set up to suit the load range specified in the data sheet in Appendix C. All motors shall be fitted with a label to draw attention to this requirement as follows: This motor has a quantity and grade of brushes fitted based upon the normal nameplate rating of the motor, which is .kW. Running this motor at a reduced load may damage the brush gear, may cause excessive brush wear and carbon dust build-up, caused by over-brushing and/or incorrect selection of brush grade for the duty. If the motor is run at a reduced load brushes must be reduced as per the table below to avoid failure:

Status Load Case 1 Load Case 2 Load Case 3 Load Case 4 Load Case 5 Full Brushing Remove 1 Brush /Ring Remove 2 Brushes/Ring Remove 3 Brushes/Ring Remove 4 Brushes/Ring

Current Range

kW Loading

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VERSION 1 14 JANUARY 2013 COPYRIGHT

The above recommendations are for short term operating conditions only and the motor should not be run continually at reduced load without reference/approval from the manufacturer, as the brush grade may also need to be changed. When changing and/or reducing brush quantity the filters must always be cleaned thoroughly and carbon dust cleaned from the brush gear compartment to avoid flashover and failure. Figure 1: Brush Information Label 4.2.21.2 Brushgear housing The brush gear shall be housed in a separate enclosure that is segregated from the stator cooling circuit. The enclosure shall have a minimum enclosure rating of IP 55. Comprehensive measures shall be taken to minimise the contamination of the stator winding with carbon dust. Preference will be given to the brush gear housed in a separate enclosure, preferably on the outboard side of the non-drive end bearing. If external rings are offered, adequate means must be adopted to ensure that the leads in the shaft tunnel are rigidly secured to avoid vibration and subsequent failure. Washable filters are to be fitted, to collect dust from the brushes; they shall be located in such a way that removal or cleaning of the filters will not cause a build-up of dust, in the enclosure, thus increasing the chances of an electrical flash-over. Differential pressure monitoring of the filters should be included. 4.2.21.3 Slip rings and brushes The Contractor shall provide full details of the construction of the sliprings, the materials used and the method of fitting to the shaft. Open ventilated type slip rings shall be used; moulded type slip rings are not permitted. The slip ring assembly shall be removable for repair purposes and have tapped pulling bolt holes for removal. The slip rings shall have excess material to allow undercutting of the slip rings whenever necessary. The slip ring shall have a mark to indicate the excess material. The ring minimum diameter shall be marked on the motor nameplate or a separate slip ring nameplate. If a helical groove is machined in the slip rings it shall be the full depth of the excess ring material. The slip ring shall be skimmed after fitting to the motor shaft. The voltage rating of the slip rings shall be conservative. Particular emphasis shall be placed on the electrical clearance between slip rings and earth. The brush boxes shall be constant pressure type and the brush grade to be used shall be marked on the motor nameplate.

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4.2.22

Core The motor stator and rotor cores shall be built from separately insulated core fully processed plates free from burrs and the inner periphery of the stator shall be concentric with the frame spigots. The laminations shall be coated with C5 type material or better to ASTM A976 Standard Classification of Insulating Coatings by Composition, Relative Insulating Ability and Application. The rotor core shall be assembled from laminations of the same grade as that used for the stator; higher loss steel is not acceptable. The individual core lamination segments shall be rotated during the core assembly, stacking or manufacturing process in order to ensure that the length of the core is uniform. The cores shall be capable of withstanding repeated heating in winding burnout ovens at 380 C. The stator and rotor cores pack shall be clamped in such a manner as to ensure a tight core under all operating conditions. The design of the core clamping system shall be such as to allow the core to be unclamped, repaired and re-stacked in the event of core damage. Only solidly fabricated one-piece finger plates are to be used to provide radial air ducts and to secure end laminations. Individual fingers fitted at these locations shall not be permitted. The stator core, in addition to the friction fit into an accurately machined casing, shall be keyed, doweled or pinned to prevent rotation of the core. The rotor core shall be keyed to the shaft or rotor spider. Rotor core clamp bolts are to be of good quality steel but manufactured of steel that is readily available locally and not of a quality better than EN9. Nuts are to be locked and tack welded or enclosed in a casing to prevent nuts unfastening or damaging the windings, should be bolts break.

4.2.23

Winding insulation system (stator and wound rotor)

4.2.23.1 General The thermal rating of the stator insulation system shall be minimum class F in accordance with the requirements of IEC 60085 Electrical insulation - Thermal evaluation and designation, both for thermal endurance and for retention of mechanical properties at class F temperatures (that is, 155 C hot spot). See section 4.2.8 Thermal Performance for details of insulation operating temperature. In addition to the requirements stipulated below, the stator winding insulation system, in its entirety, shall possess service proven performance. The minimum requirement for an adequate service record is 15 years satisfactory performance in MV motors, which can be verified through independent references. On request the contractor shall provide a list of such references with contact details.

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If any aspect of the system offered (for example operating voltage, bracing system, manufacturing facility where the coils or bars are manufactured or inserted into the stator or rotor core and so forth) has not been proven for 15 years then the full details of the change and of the associated components and or processes shall be submitted to the engineer for approval. The system shall be designed for operation in a humid, wet and dirty environment with contamination by dust and slurry. The power supply must be considered as being of poor quality particularly regarding transient disturbances. The stator insulation shall be vacuum pressure impregnation (VPI) system. After winding and bracing the compete stator shall be vacuum pressure impregnated with a solventless resin. That is, the impregnating medium in the VPI process shall consist of 100% reactive components. The stator insulation shall be a sealed system which is capable of successfully meeting the requirements of NEMA MG1 section 20.18.2. Evidence of such performance shall be provided in the form of a witnessed type test for the stator insulation system. 4.2.23.2 Main Ground Insulation The main ground insulation system shall consist of continuously taped glass or polyethylene terephthalate film backed mica paper tape, over the slot and endwinding portions. The main wall thickness in the slot portion shall be determined by applying a maximum design insulation stress of 2 kV/mm (calculated using operational phase voltage to earth=Un/3), but shall not be less than 1.0 mm radial thickness irrespective of the rated voltage Un. The calculation for the voltage stress shall be based solely upon the glass or polyethylene terephthalate backed mica paper tape main insulation. The voltage stress in the main wall shall not exceed 2.8 kV / mm. 4.2.23.3 Strand / Turn Insulation The strand / turn insulation system shall consist of continuously taped glass or polyethylene terephthalate film backed mica paper tape, over the entire conductor. The strand insulation thickness shall be determined by the contractor to have adequate mechanical strength to withstand coil manufacturing processes and to withstand the inter-turn transients in tests and service. The strand insulation thickness shall not be less than 0,22 mm radial thickness, irrespective of the rated voltage Un. Two section series coils (that is two tiers of conductors, all strands connected in series by one of several arrangements) shall use either a Roebel transposition or shall be connected such that the maximum voltage between strands is 50% of the voltage between coil leads.

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4.2.23.4 End winding & Lead Clearances The contractor shall calculate the required air clearances between winding parts and from winding to ground in all regions of the end winding, connections and leads (including ETD leads, stator winding termination leads and so forth) such that no potentially destructive PD (for example, no continuous PD in the same location) will occur in service using the contractors usual methods of calculation. However, if the service altitude is over 1 000 m, instead of using the rated voltage Un, the contractor shall use an effective voltage (Ueff) which shall not be less than that obtained by dividing the nominal voltage, Un, by the relative air density as defined below:

U eff

Un e
H 8150

Where H is the design altitude, in meters above sea level. 4.2.23.5 Bracing The end-winding shall be securely braced to prevent deleterious vibration, deterioration of insulation properties, in normal service as well as to prevent excessive movement under short circuit conditions. Rigid glass filled and resin bonded packing blocks or bracing cords shall be of adequate dimensions. 4.2.23.6 Slot and Endwinding Partial Discharge Control Measures Notwithstanding the normal practice of the contractor, the need for a corona shield (slot outer corona protection) and for ECP shall be determined according to the table below using the same value of Ueff as defined above: System Component OCP ECP Verify OCP resistance to ground Minimum Requirement for Partial Discharge Protection Ueff < 5.5kV Ueff 5.5kV Yes Yes No Yes No Yes

Figure 2: Corona shield and End Corona Protection 4.2.23.7 Requirement for OCP The following shall apply to the OCP on all coils: a) b) The length of the corona shield is such that the end of the corona shield is never before the end of the core press fingers. The coil or bar is fitted into the slot in such a way that reliable and regular contact is made between the corona shield and core along the complete length of the slot on at least one side of the coil or bar. The quality of such contact is verified by measurement of the contact resistance between corona shield and core at least once on every bar or coil side, after VPI.
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c)

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VERSION 1 14 JANUARY 2013 COPYRIGHT

4.2.24

Requirement for ECP On coils or bars that are provided with ECP it is required that: a) b) The active length of the ECP is in accordance with the contractors standards for Ueff but with a minimum of 50 mm. The length of the overlap with the corona shield is in accordance with the contractors standards for Ueff, but with a minimum of 20mm. This means that the overall length of the ECP shall never be less than 45mm.

4.2.25

Winding Embedded Temperature Detectors (ETDs) ETDs shall be fitted to all stator windings as specified below. The sensing elements of the ETDs shall be a Resistance Temperature Detector (RTD) of the wire wound Platinum 100 ohm type, embedded in an epoxy glass laminate. The RTDs shall be three or four wire types and the sensing elements shall meet the requirements of IEC 60751 Class B. The ETDs shall be dual element and shall not be regarded as being two RTDs in one. There shall be a minimum of 6 functional ETDs fitted, with an equal number in each phase of the winding. The thermal profile of the windings shall be determined by type testing or numerical simulation. The thermal profile is required purely to ensure that the ETDs are installed in the hottest location. The physical position of the ETDs shall be: a) b) c) d) One ETD per slot. All ETDs shall be in the slot between top and bottom coil sides. All ETDs shall be positioned axially at the hottest end of the slot as determined from the thermal profile. At least three of the ETDs shall be located in slots as close as possible to the hot spots as determined from the thermal profile, with an equal number per phase. The ETDs shall be wired to terminals and used to monitor stator winding temperature. At least three ETDs shall be located approximately uniformly distributed around the winding, but in slots chosen for coil sides that are electrically as close as possible to the line terminals. These ETDs shall be wired to terminals and will be used (by others) to measure partial discharge and / or temperature.

e)

ETD leads shall not be allowed to come into contact with the endwindings of the coils. They shall be secured and protected to prevent risk of mechanical damage during handling in manufacture and assembly in the factory as well as during assembly and subsequent maintenance on site. Additional requirements for clearances are given section 4.2.25.4End winding & Lead Clearances.

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MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

4.2.26

Wound (slip ring) rotor The rotor winding shall be as for the stator winding and shall be star connected. The rotor open circuit shall preferably less than 1 000 V and the Contractor shall indicate the actual open circuit voltage in the data sheet.

4.2.27

Cage rotor For a cage rotor the materials used, the cross sectional shape of the bars and end rings, the method of manufacture, the method of support and the brazing system shall be approved by the Engineer. If cuprous bars are used a rectangular profile rather than a sash or T-bar profile is preferred. The bar size and shape shall be approved by the Engineer. Brazing of bars to the end ring shall all be done using an induction heater process. The rotor end rings shall be of solid forged construction. Split end rings having the joint brazed will not be accepted. Cast end rings may only be used if a calculation of the stresses in the end ring may prove to be safe. However, cast end rings shall not be used in two pole machines or machines exceeding 500 kW. If the winding is an aluminium die-casting, a high-pressure injection method rather than a centrifugal casting method is preferred. A centre ring is non-preferred and if used shall be exposed rather than inside the core and be approved by the Engineer. If the rotor die-casting comprises two cages cast together or welded together, the manufacturing detail will need to be approved by the Engineer. The cage rotor shall be suitable for the starting duty given in the data sheet. Contractors shall indicate the number of starts in quick succession the motor is designed for and the maximum estimated temperature rise of the rotor bars and end rings during these starts for a "cold" and "hot" rotor. The contractor shall state the energy dissipated in the rotor per start, on which design calculations have been based.

4.2.28

Anti-condensation heaters An anti-condensation heater shall be fitted in the motor frame suitable for connection in series or parallel for both operation off both a 220 and 110 volt AC 50 Hz single phase supply.

4.2.29

Main Terminal Boxes and Surge Suppression Motors shall be provided with approved terminating fittings for the required cables. Where a particular type and size of motor is supplied for several different applications, the arrangement of cable terminating fittings shall permit inter-changeability of motors and allow one spare motor to serve for all applications without having to modify the existing cable arrangement. Horizontal motors smaller than 335 frame size shall be fitted with terminal boxes that allow cable entry from any one of four positions, 90 apart, on top of the motor. A spreader/adaptor box, and cable gland or removable gland plate, shall be provided to accommodate the cable and cable tails.

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MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

On motors of frame size 335 and above, all six phase ends of the stator winding shall be brought out to two terminal boxes, one on each side of the stator, which shall be interchangeable. Unless otherwise approved, motors shall be delivered with the cable boxes or gland plates fitted to the right hand terminal box when viewed from the drive end. The opposite terminal box shall be complete with a neutral connection and all fittings and shall be totally enclosed. Terminal boxes and cable boxes shall be provided complete with the internal parts, all fittings and cable glands required to connect the motor for operation. Terminal box lids shall have lips over the terminal box flange, so that the gasket will not be exposed to water and dust. Terminal boxes shall be extremely robust and fabricated from plate (mild steel or better) of minimum of 3 mm thickness and shall have a rupturable membrane designed to prevent damage to the terminal box in the event of internal pressure build up and release the gases in such a manner as not to endanger persons. A breather shall be fitted to allow free breathing of the terminal box but prevent water ingress from rain or from washing down with a high pressure hose. The dimensions of terminal boxes and cable boxes shall be adequate for accommodating the sizes and types of cable specified. The design of the terminal box shall permit the removal of the motor without the need to disturb the termination or bend the cable appreciably. Motors rated for 3300 V and above shall have provision made, in the terminal box or connecting chamber, for receiving an approved surge suppression unit. The space shall be provided whether or not the surge suppresser is supplied and fitted. The surge suppression shall be of an approved type and shall be housed in a separate compartment in the main terminal box to that for the stator line connections. Bushings through the dividing wall between two sections of the main terminal box shall connect the stator windings to the surge suppression devices. The failure of a surge suppressor shall not cause any damage to the stator terminal connection compartment of the main terminal box. NOTE: Surge suppression cannot be fitted on motors driven by a variable speed drive and must be excluded from motors that will be speed controlled. Given that motors may be connected in either star or delta, depending on the stator voltage, the terminal box used for making the connection must be large enough for the terminating, and making off the external cables used for a delta connection. Gland to the terminal distances and air clearances must not be less than the same dimensions in the main stator terminal box. The cable shall be terminated suitable to be heat shrink insulation terminated and the following minimum air clearances inside the cable box (allowing for cable lugs) are required as listed in Table 13.
Ueff 10 000V 180 mm 120 mm 180 mm Ueff 6 000V 120 mm 90 mm 120 mm Ueff 2 300V 90 mm 60 mm 90 mm

Length of insulator Phase to earth Phase to phase

Figure 3: Terminal box minimum clearances

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AA SPEC 538011

MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

Where interchangeability is requested, cable boxes shall be as required in Schedule C. All stator connections and rotor winding clips are to be brazed. Soldered connections are not acceptable. The rotor cable box for wound rotor slip ring motors shall be separate from the main terminal box, but otherwise similar. 4.2.30 Stiffness The diameter and length of the rotor core and distance between bearing centres shall be selected to provide a machine having an exceptionally rigid shaft, except in the case of two pole machines that operate above the critical speeds. The maximum shaft deflection under the worst condition of unbalanced magnetic pull including deflection due to the mass of the shaft and rotor core, eccentricity due to bearing clearances, spigot clearances etc., shall not exceed 10 per cent of the air-gap. Specifically with motors with pedestal bearings or a movable stator core design, this 10 per cent will be made up off: a) b) 4.2.31 A maximum (deliberate) initial static displacement of the shaft vertically down not greater than 5% of the air-gap. Assuming the 5% worst-case initial displacement a maximum additional deflection of the shaft due to unbalanced magnetic pull not greater than the remaining 5% of the air-gap.

Balancing The completely assembled rotor with fans and shaft with half keys shall be balanced both statically when stationary and dynamically at rated motor speed. The rotor` shall be fitted with balancing rings to which weights can be attached for balancing. Weights shall not be fitted to blades of fans. Balance weights shall be made from steel or approved material and fixed into position with high tensile steel bolts locked into position. Balance weights shall be recessed and shaped to suit the area where fitted.

4.2.32

Earthing of motor The motor shall be fitted with a main earth connecting stud welded to the stator frame. The stud shall be situated near the main stator cable box to facilitate bonding of the cable sheath and earth conductor to the earth stud. All non-electrical installation parts of the stator shall be suitably bonded to this main earth.

4.2.33

Lifting facility Lifting lugs shall be provided for slinging the motor without spreader bars.

4.3 4.4

Material Properties Mechanical Properties

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MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

4.5 4.6

Electrical Properties Corrosion Protection

Corrosion protection shall comply with the requirements of AA Specification 164050 and AA CPS. When the site conditions are corrosive, as described by the Engineer in the data sheet, the materials and corrosion protection shall be agreed between the Contractor and the Engineer.

QUALITY ASSURANCE PROVISIONS

The requirements of AA REQ 100 shall apply. The machine manufacturer shall be accredited with a) b) c) ISO 9001 ISO 14000 ISO 18000

In addition to the requirements of AA REQ 100 Quality Requirements for Suppliers of Critical Equipment, before manufacture commences, the contractor shall submit a quality control plan to the engineer so that he can indicate which tests will be witnessed.

6
6.1 6.2 6.3
6.3.1

TEST AND INSPECTION METHODS

Chemical Tests Mechanical Tests Electrical Tests
General The following tests shall be performed on every machine: a) b) Routine tests Special tests: 1. 2. 3. 4. 5. Core loss test Tan delta on the complete stator No load bearing run Determination of efficiency Vibration

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MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

c)

Type tests

Where selected by the engineer in Appendix C, additional optional tests shall be performed as detailed in IEC 60034-1 Rotating electrical machines. Part 1: Rating and performance and IEC 60034-9 Rotating electrical machines. Part 9: Noise limits. Copies of all test certificates, including the type tests, shall be included in the project documentation. The test certificate shall indicate the test conditions (such as the number of turns of the test cable, the current drawn and the flux density in the case of the core flux test see 6.3.2 below). 6.3.2 Routine tests Routine tests shall be performed on every machine, as described in IEC 60034-1 Rotating electrical machines. Part 1: Rating and performance. 6.3.3 Special tests The following special test shall be performed on each machine supplied to this specification: 6.3.3.1 Core loss test A core loss test shall be performed for the stator core on its own and for the stator core in the frame, as a routine test for every motor. This data will be used to assess the suitability or otherwise of the core for future rewinds, during the life of the motor. 6.3.3.2 Tan delta on the complete stator Tests shall be carried out on all completed machines with a rated stator voltage 3 300V to assess the quality of the dielectric on the completely wound machine. Measurements shall be made at room temperature on each phase of the winding separately, the other phases being earthed and then on the complete winding (with the phases in parallel). This test shall be performed at the motors rated supply line frequency (that is, 50 Hz or 60 Hz.) Reduced frequency testing is not acceptable. With the rated stator line voltage designated as Un, the Tan Delta values shall be measured at 0.2 Un increments between 0.2 Un and 1.0 Un. The initial value of 0.2 Un, the value of half of the increment between 0.2 Un and 0.6 Un and the maximum increment per 0.2 Un shall not exceed the values specified in figure 4 below. Maximum value of Tan Delta at 0.2 Un 0.0200 Maximum Value of 0.5 (Tan Delta at 0.6 Un - Tan Delta at 0.2 Un) 0.0060 Maximum Value Of Delta Tan Delta per 0.2 Un increment 0.0060

Figure 4: Tan delta test limit values for coils The capacitance shall also be recorded at each measuring voltage.

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AA SPEC 538011

MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

6.3.3.3 No load bearing run The machine shall be operated at no load as defined in IEC 60034-1 Rotating electrical machines. Part 1: Rating and performance and the temperature of the bearings monitored. The test shall continue until all bearing temperatures stabilise. 6.3.3.4 Determination of Efficiency In Appendix C the contractor shall state, with reference to IEC 60034- 2 Rotating Electrical Machines. Part 2-1: Standard methods for determining losses and efficiency from tests (excluding machines for traction vehicles), what method is proposed to be used to prove the machine losses. 6.3.3.5 Vibration tests Each machine shall be tested as per section 4.2.9 Vibration. 6.3.4 Type tests For each machine type, the contractor shall submit to the engineer for his approval a type test certificate on an identical machine. If a type test has not been performed before on an identical machine, then a type test shall be performed on each machine type for which no type test certificate exists. Where a type test is required, a full load temperature rise performance test shall be carried out on one motor of each type, as described in 60034-1 Rotating electrical machines. Part 1: Rating and performance. If more than one identical motor is ordered, only one motor shall be tested.

6.4

NDE

7
7.1 7.2

MARKING AND PACKING

Marking Packing
The motor shall be suitable packed and crated for delivery. The shaft shall be clamped for transport, to safeguard the bearings. Any extra support equipment or packing that it is necessary to remove before putting the machine into service is to be painted in a distinctly different colour to the main machine and bold notices to this effect affixed to the machine.

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MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

APPENDIX A: REFERENCED DOCUMENTS The latest issue of the following documents is deemed to form part of this specification: AA REQ 100 AA SPEC 166000 AA SPEC 232001 AA SPEC 538032 : : : : Quality Requirements for Suppliers of Critical Equipment Lubricants general requirements Reconditioning of white metal bearings Shafts for electric AC induction machines with frame sizes 355 and larger Standard Classification of Insulating Coatings by Composition, Relative Insulating Ability and Application Rotating electrical machines. Part 1: Rating and performance Rotating electrical machines Part 12: Starting performance of singlespeed three-phase cage induction motors Rotating Electrical Machines. Part 14: Mechanical vibration of certain machines with shaft heights of 56 mm and higher- Measurement, evaluation and limits of vibration severity Rotating Electrical Machines. Part 15: Impulse voltage withstand levels of form-wound stator coils for rotating a.c. machines Rotating Electrical Machines. Part 2-1: Standard methods for determining losses and efficiency from tests (excluding machines for traction vehicles) Rotating electrical machines Part 2-2: Specific methods for determining separate losses of large machines from tests - Supplement to IEC 60034-2-1 Rotating electrical machines Part 23: Specification for the refurbishing of rotating electrical machines Rotating electrical machines Part 27: Off-line partial discharge measurements on the stator winding insulation of rotating electrical machines Rotating electrical machines Part 5: Degrees of protection provided by the integral design of rotating electrical machines (IP code) Classification Rotating Electrical Machines. Part 6: Methods of cooling (IC Code)

ASTM A976

IEC 60034-1 IEC 60034-12

: :

IEC 60034-14

IEC 60034-15

IEC 60034-2-1

IEC 60034-2-2

IEC 60034-23

IEC 60034-27

IEC 60034-5

IEC 60034-6

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VERSION 1 14 JANUARY 2013 COPYRIGHT

IEC 60034-7

Rotating electrical machines Part 7: Classification of types of construction, mounting arrangements and terminal box position (IM Code) Rotating electrical machines Part 8: Terminal markings and direction of rotation Rotating Electrical Machines. Part 9: Noise limits Electrical insulation - Thermal evaluation and designation High-voltage switchgear and controlgear Part 202: High- voltage/lowvoltage prefabricated substation MOTORS AND GENERATORS

IEC 60034-8

IEC 60034-9 IEC 60085 IEC 622271-202

: : :

NEMA MG 1

APPENDIX B: RECORD OF AMENDMENTS Version 1 : New document (P Warner, January 2012)

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AA SPEC 538011

MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

APPENDIX C: DATA SHEET TO BE COMPLETED BY THE ENGINEER AND THE CONTRACTOR FOR EACH MOTOR TYPE Not all data will be available at the tender stage but will be required at the contract stage.
TO BE COMPLETED BY ENGINEER TO BE COMPLETED BY THE CONTRACTOR

CLAUSE NO 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 2.0 2.1 2.2 2.3 2.4 2.5 2.6 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 Rating Rated output kW Rated voltage V Temperature rise when operating continuously at voltage range System fault level Frequency Hz Duty No. of poles (2, 4, 6, 8 etc) Synchronous speed r/min Grounding system type: Soild/NER/NEC Ground current limited to Site conditions Maximum altitude above sea level Maximum ambient air temperature Minimum ambient air temperature Cooling water maximum temperature Cooling water specification Corrosion protection Enclosure Enclosure material (steel, cast steel or cast iron) Air cooled CACA IP55 Water cooled CACW IP55 Totally enclosed fan cooled TEFC IP55 Open Drip Proof IP22 Pipe Ventilated IP22 NEMA Type WP II
COMPANY CONTRACTUAL

4.2.2 4.2.4 4.2.6 4.2.4 4.2.4 4.2.2 4.2.2 4.2.2 4.2.5 4.2.5 50 / 60 Hz S1 Zone A and B kA

4.2.3 4.2.3 4.2.3 4.2.3 4.2.3 4.6

m C C C

required. Manufacturers standard pro

4.2.14 4.2.14 4.2.14 4.2.14 4.2.14 4.2.14 4.2.14

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MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

4.0 4.1 4.2 4.3 4.4 4.5 4.6 5.0 5.1 5.2 5.3 5.4 6.0 6.1 6.2 6.3 6.4 6.5 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12

Cooling system SABS IEC 60034-6 Classification CACA (IC5A1A1 or IC6A1A1) CACW (IC8A1W7) TEFC (IC4A1A1) Open ventilation (IC0A1) Pipe ventilated (IC1A1 or IC2A1 or IC3A1) NEMA weather protected Type II Water cooling system Water Cooling water inlet temp. C Cooling water outlet temp. C Cooling water flow rate l/s Water cooler maximum pressure kPa Limitations for transport or interchangeability Shaft height Length Width Height Mass Motor dimensions Shaft height Length Width Height Mass Motor frame size Motor assembly critical speed Rotor diameter (D) (metres) Rotor active core length(L)(metres) D2L (cubic metres) Ratio L/D Rotor mass (Kg) 4.2.14 4.2.14 4.2.14 4.2.14 4.2.14 4.2.14 4.2.12 4.2.30 4.2.13 4.2.13 4.2.13 4.2.13 4.2.13 4.2.14 4.2.14 4.2.14 4.2.14 4.2.14 4.2.15 4.2.15 4.2.15 4.2.15 4.2.15 4.2.15 4.2.15 4.2.15 4.2.15 4.2.15

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MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

7.13 7.14 7.15 7.16 8.0 8.1 8.2 8.3 8.4 9.0 9.1 10.0 10.1 10.2 10.3 11.0 11.1 11.2 11.3 11.4 11.5 11.6 12.0 12.1 12.2 12.3 12.4 12.5 12.6 12.7

Distance between bearing centres (Metres) Motor shaft centre height Motor air gap (on radius) Motor direction of rotation (bi-directional /CW or CCW facing DE) Winding insulation system Stator winding class of insulation Wound rotor winding class of insulation Stator slot wedges (Magnetic / non-magnetic material) Date on which Engineer approved insulation system Motor stator Power supply cable type and size Motor rotor Motor rotor winding (Cage/Wound rotor) Slip rings (continuous running/brush lifting and shorting gear) Wound rotor open circuit voltage Bearings Bearing type. (Grease lubricated ball/roller / Oil lubricated sleeve end shield mounted / Oil lubricated sleeve pedestal) Bearing manufacturer Oil lubrication cooling. (Natural / Force lubrication / Water jacket cooling) Sleeve bearing end float (total) Grease lubrication interval Ball and roller bearing life Driven load Pump/fan/mill/crusher/conveyor etc. Manufacturer/supplier Type number Inertia (referred to motor shaft) Torque/speed curve of driven load Direct drive/belt drive/gearbox etc Coupling type

4.2.13 4.2.30 4.2.13 4.2.19 4.2.7 4.2.18 4.2.6 4.2.23 4.2.26 4.2.23 4.2.23.1

F F

4.2.4

4.2.26 4.2.27 4.2.21 4.2.26

4.2.20 4.2.20 4.2.20.1 4.2.20.1 4.2.20.2 4.2.20.2

4.2.8 4.2.8 4.2.8 4.2.8 4.2.8 4.2.8 4.2.8 4.2.17

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MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

12.8 13.0 13.1 13.2 13.0 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 13.9 13.10 13.11 13.12 13.13 13.14 13.15 13.16 13.17 13.18 13.19 13.20 13.21 13.22 13.23 13.24

Coupling to be fitted by motor manufacturer (yes/no) Vibration IEC Vibration standards NEMA Vibration standards Motor Performance Motor full load current at rated output, voltage and frequency Temperature rise of windings measured by resistance when operating at rated voltage and frequency (Guaranteed) Calculated temperature rise of windings when operating at any point in Zone A Calculated temperature rise of windings when operating at any point in Zone B Duty Load at which the Contractor guarantees losses and power factor No load losses at Duty Point (Guaranteed) Power factor at Duty Point (Guaranteed) Number of hours per year that the motor will be operated at no load Cost of energy per hour Cost of maximum demand per month Losses at Duty Point (Guaranteed) Number of hours per year that the motor will be operated at duty point load Interest rate Number of years over which losses will be capitalised Efficiency at rated output, voltage and 1 frequency Efficiency at 75% rated output, rated voltage and frequency Efficiency at 50% rated output, rated voltage and frequency Peak efficiency at % of rated output at rated voltage and frequency Power factor of motor only at rated output, voltage and frequency Power factor of motor only at 75% rated output, rated voltage and frequency Power factor of motor only at 50% rated output, rated voltage and frequency Capacitor rating to achieve power factor of 0.85 at rated full load, voltage and frequency (kVAR) No. of consecutive starts from cold No. of consecutive starts from hot
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4.2.8

4.2.9.1 4.2.9.2

4.2.6 4.2.6 4.2.6 4.2.6 4.2.7 4.2.27 4.2.27 4.2.27 4.2.27 4.2.27 4.2.27 4.2.27 4.2.27 4.2.27 4.2.7 4.2.7 4.2.7 4.2.7 4.2.7 4.2.7 4.2.7 4.2.7 4.2.10 4.2.10
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MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

Energy dissipated in the stator per start Energy dissipated in the rotor per start 13.25 Maximum stator temperature after the number .of consecutive starts from cold and hot as 3 stated in 13.22 & 13.23 above. Maximum rotor temperature after the number of consecutive starts from cold and hot as stated in 13.22 & 13.23 above. Maximum permissible stall time from cold without damaging the motor (secs) Maximum permissible stall time from hot without damaging the motor (secs) Maximum number of starts expected for the life of the motor No load current (X rated full load current) at rated voltage and frequency No load power factor at rated voltage and frequency Starting (locked rotor) current (X rated full load current) at rated voltage and frequency Starting (locked rotor) power factor at rated voltage and frequency Full load torque at rated output, voltage and 3 frequency (Guaranteed) Starting (locked rotor) torque (X rated torque) Peak torque (X rated torque) Run up time (secs) Critical speed (% of synchronous speed) Slip as % of rated synchronous speed at rated output, voltage and frequency Optional tests required Heat run and efficiency test certificate from previous machine (yes/no) Heat run and efficiency test to be included in this supply (yes/no) Test method to be used to prove guaranteed performance (Actual / Equivalent load method) Noise level test (yes/no) Momentary overload test (yes/no) Torque/speed curve test (yes/no) Optional items Motor base plate (yes/no)

4.2.27 4.2.27 4.2.10 4.2.10

13.25 13.26 13.27 13.28 13.29 13.30 13.31 13.32 13.33 13.34 13.35 13.36 13.37 13.38 14.0 14.1 14.1 14.2 14.3 14.4 14.5 15.0 15.1

4.2.10 4.2.10 4.2.10 4.2.2 4.2.2 4.2.2 4.2.2 4.2.2 4.2.2 4.2.10 4.2.10 4.2.12 4.2

6.3.4 6.3.4 6.3.3.4 4.2.7 6.3.1 6.3.1 6.3.1

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VERSION 1 14 JANUARY 2013 COPYRIGHT

APPENDIX D: CERTIFICATE OF COMPLIANCE. TO BE COMPLETED BY CONTRACTOR The equipment offered complies fully with the Anglo American Specification 538011 Medium Voltage Induction Motors clauses as follows: CLAUSE NO. 1.0 2.0 3.0 4.1 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9.1 4.2.9.2 4.2.10 4.2.11 4.2.12 4.2.13 4.2.14 4.2.15 4.2.16 4.2.17 4.2.18 4.2.19 4.2.20 4.2.20.1 4.2.20.2 4.2.21.1 4.2.21.2 4.2.21.3 4.2.22 4.2.23.1 4.2.23.2 4.2.23.3 4.2.23.4 4.2.23.5 4.2.23.6 4.2.23.7 4.2.24 4.2.25 4.2.26 4.2.27 4.2.28
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COMPLIANCE YES/NO

REMARKS

AA SPEC 538011

MEDIUM VOLTAGE INDUCTION MOTORS

VERSION 1 14 JANUARY 2013 COPYRIGHT

4.2.29 4.2.30 4.2.31 4.2.32 4.2.33 4.3 4.4 4.5 4.6 5.0 6.1 6.2 6.3.1 6.3.2 6.3.3 6.3.3.1 6.3.3.2 6.3.3.3 6.3.3.4 6.3.3.5 6.3.4 6.4 7.1 7.2

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