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NUMBER E06-S04

REV. NO. 1
ENGINEERING STANDARD DATE APR 2001
PAGE 1 OF 11

Motors, DC

This document is issued by Engineering Standards Section, SABIC R&D Complex, PO Box 42503, Riyadh 11551, Kingdom of Saudi Arabia.
The information contained in this document is the confidential property of SABIC. It can not be disclosed, copied or used for any purpose
without prior approval from SABIC. If you are not authorized to possess this document, please destroy it immediately.
NUMBER E06-S04
REV. NO. 1
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DATE APR 2001
ENGINEERING STANDARD PAGE 2 OF 11

CONTENTS

1. SCOPE ................................................................................................ 3
2. REFERENCES 3
3. GENERAL 3
4. ENVIRONMENTAL REQUIREMENTS ................................................ 4
4.1 Site Conditions 4
4.2 Service Conditions 4
5. ELECTRICAL DESIGN ....................................................................... 4
5.1 General 4
5.2 Power Source 4
5.3 Motor Type ..................................................................................... 4
5.4 Windings and Insulation 5
5.5 Armature 5
5.6 Commutator and Brushes .............................................................. 5
5.7 Performance 5
5.8 Terminal Boxes 6
5.9 Motor Leads ................................................................................... 6
5.10 Auxiliary Cooling Fans 6
5.11 Space Heaters 6
5.12 Provisions for Grounding ................................................................ 7
5.13 Conduit and Wiring 7
6. MECHANICAL DESIGN FEATURES 7
6.1 Hazardous Areas ........................................................................... 7
6.2 Motor Enclosures 7
6.3 Bearings and Lubrication 8
6.4 Shafts ............................................................................................. 8
6.5 Balancing and Vibration 9
6.6 Mounting 9
6.7 Noise Level .................................................................................... 9
7. NAMEPLATES 9
7.1 Motor Nameplate 9
7.2 Accessory Tags .............................................................................. 9
8. TEST AND INSPECTION 9
9. FINISH 10
10. DOCUMENTATION ........................................................................... 10
10.1 Drawings 10
10.2 Operation and Maintenance Manual 11
11. PREPARATION FOR SHIPMENT ......................................................11
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DATE APR 2001
ENGINEERING STANDARD
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1. Scope
This specification is for manufacturing, testing and shipping of dc motors.

2. References
Reference is made in this specification to the following documents. The latest issues, amendments, and
supplements to these documents shall apply unless otherwise indicated.
SABIC Engineering Standards (SES)
E06-S01 Induction Motors 150kW (200 HP) and Below
E06-X04 Motors, DC-Data Sheets
S20-G01 Plant Equipment Noise Limits
Q01-G02 General Surface Preparation and External Painting of Equipment
Z01-G04 Measurement Units for Use in SABIC Projects
American National Standards Institute (ANSI)
B1.1 Unified Inch Screw Threads (UN and UNR Thread form)
Anti-Friction Bearing Manufacturers Association (AFBMA)
Std 9 Load Rating and Fatigue Life for Ball Bearings
Std 11 Load Rating and Fatigue Life for Roller Bearings
Institute of Electrical and Electronic Engineers (IEEE)
113 Guide on Test Procedures for DC Machines
304 Test Procedure for Evaluation and Classification of Insulation Systems for DC Machines
National Electrical Manufacturers Association (NEMA)
MG-1 Motors and Generators
National Fire Protection Association (NFPA)
70 National Electrical Code (NEC)

3. General
4.1 This specification prescribes the general requirements for dc motors. See SES E06-X04 for specific
requirements.
4.2 SABIC may choose to accept motors manufactured to other standards when it can be shown that they
meet or exceed the requirements of the referenced standards. Vendor shall provide with proposal a
detailed listing of the applicable standards, and a chart comparing requirements of the proposed standard
with those of the referenced standards.
4.3 Whether the motor is supplied by the engineered equipment vendor or purchased directly by SABIC, it
shall be the engineered equipment vendor’s responsibility to establish the required motor ratings and to
ensure that the motor is properly matched to the load, for satisfactory operation under actual site
conditions.
4.4 All motors furnished by one vendor and having identical ratings shall be mechanically and electrically
interchangeable.
4.5 Documents shall be provided in units conforming to SES Z01-G04, and shall be written in English
language.
4.6 Any conflict(s) between this specification, SES and industry standards, engineering drawings, and
contract documents shall be resolved at the discretion of SABIC.
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DATE APR 2001
ENGINEERING STANDARD PAGE 4 OF 11

4. Environmental Requirements
4.1 Site Conditions
4.1.1 Indoor Conditions
a. Temperature range: air-conditioned. 0 to 40 °C
b. Relative humidity range: 10 to 100 percent
4.1.2 Outdoor Conditions
a. Ambient temperature range: 1 to 50 °C
b. Metallic surface temperatures reaching 75 °C due to solar radiation
c. Corrosive desert atmosphere with blowing sand and dust
4.1.3 Storage/Transport Conditions
a. Ambient temperature: 2 to 70 °C
b. Relative humidity range: 1 to 95 percent, non-condensing
4.2 Service Conditions
All motors shall be suitable for continuous duty at the nameplate rating in outdoor locations with direct,
continuous exposure to the sun.

5. Electrical Design
5.1 General
5.1.1 The motors and materials shall be new.
5.1.2 Motor ratings shall be specified in kW. Full load armature and field current shall be specified at a
50 °C ambient temperature and at the base speed.
5.1.3 Multiple armature design may be supplied on motors larger than 750 kW, if approved by SABIC.
5.1.4 Motors shall be supplied with standard NEMA frames, to the extent ratings permit.
5.2 Power Source
5.2.1 DC power sources for motors shall be batteries; dc generator; variable speed drive; or rectified
power supply.
5.2.2 Motors shall supply rated output torque in continuous service, with variations of plus or minus ten
(10) percent of the rated armature or field voltage, or both, without electrical or mechanical damage to the
motor.
5.3 Motor Type
5.3.1 Engineered equipment vendor shall define the load characteristics. This definition shall include load
torque characteristics, that is, constant torque or variable torque.
5.3.2 The type of motor furnished shall be suitable for the specific application. Vendor shall furnish one of
the following general types:
a. Straight shunt wound
b. Stabilized shunt wound
c. Series wound
d. Compound wound
e. Permanent magnet
5.3.3 Proposed motor types other than those listed above shall be detailed by vendor in proposal, and
shall be subject to SABIC approval.
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5.4 Windings and Insulation


5.4.1 Unless a specific voltage is indicated in SES E06-X04, the motors shall be designed to operate at
the following dc voltage levels:
a. Armature 500, 600, 700 or 750 V dc
b. Field 150, 240 or 300 V dc
5.4.2 Motors shall be supplied with Class F insulation minimum. Insulation shall be limited to total
temperatures based on NEMA MG 1 Table 23.9 for Class F insulation in a 40 °C ambient, but with
temperature rise 10 °C less than would normally be allowed for Class F insulation due to the elevated site
temperature.
5.4.3 Field windings shall be encapsulated or epoxy resin impregnated and oven cured. Field windings
shall be bonded to the poles.
5.4.4 Motors rated above 150 kW (200 HP) shall be provided with at least two (2), 100 Ω platinum
resistance temperature detector (RTD’s) in commutator or each interpole field winding, and wired to a
terminal strip in a NEMA 4X or cast iron terminal box. The RTD’s shall be three (3) wire type, and shall be
located where the maximum temperature is located.
5.5 Armature
5.5.1 Armatures shall have low inertia, and shall be dynamically balanced at highest rated speed to a
value not exceeding those specified in NEMA MG-1.
5.5.2 Armature coils shall be made of rectangular copper conductors, individually insulated and bonded
together with separators. The fully formed coils shall be wrapped and taped with grounded wall insulation.
5.5.3 The connections of the armature coils to commutator risers and the inner pole to pole face shall be
tungsten inert gas (TIG) welded to give a high strength, low resistance and oxide free surface.
5.6 Commutator and Brushes
5.6.1 Commutator shall be constructed of insulation with silver-bearing copper commutator segments,
and shall be easily accessible for maintenance.
5.6.2 Brushes shall be copper or carbon, with current density not exceeding 50 percent of their nominal
ratings, and shall be mounted in rigid, corrosion resistant brush holders. Brush springs shall be constant
pressure, to provide stable brush position when motor is operated in either direction, and shall require no
adjustment. Both brushes and holders shall be individually replaceable, and shall be easily accessible for
maintenance. Replacement brush catalog number shall be listed on motor nameplate.
5.6.3 When specified in SES E06-X04, redundant or duplicate brush assemblies shall be provided, to
minimize the periodic brush replacement.
5.6.4 The brushes shall be provided with vibration dampening pads and brush wear monitoring system.
The monitoring system brush leads shall be wired to a separate terminal box.
5.6.5 A high-impact, clear poly-carbonate metal-frame window shall be provided, to allow visual
inspection of the brushes and commutator while motor is in operation.
5.7 Performance
5.7.1 Motor starting current shall be limited to 250 percent of full load current unless a higher value is
approved by SABIC.
5.7.2 Motor shall be capable of multiple starts without injurious overheating and without permanent
damage to motor. Vendor shall state in proposal all limitations related to repetitive starts, if any.
5.7.3 Motors shall be designed to meet the overload capacity specified in NEMA MG1-23.10 for general
industries motors. In addition, the motors shall have the following overload capabilities at rated voltage
throughout the rated speed range:
a. 1.15 times the rated kW (HP) for continuous operation
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DATE APR 2001
ENGINEERING STANDARD PAGE 6 OF 11

b. 1.25 times the rated kW (HP) for 2 hours


5.7.4 Motor torque shall be capable of overcoming maximum inertia and load torque on starting, and of
accelerating the load to rated base speed under the rated and reduced voltage conditions specified in 5.2
during starting, without injurious heating.
5.7.5 Motor base speed shall be determined based on rated field voltage and rated armature voltage.
Motors shall be capable of delivering the maximum required load torque without exceeding the motor
nominal base speed rating.
5.7.6 Motors shall be capable of withstanding an overspeed of 25 percent above the rated base or highest
operating speed, whichever is greater, for a period not exceeding 2 minutes.
5.8 Terminal Boxes
5.8.1 Terminal boxes shall be cast iron, oversized and diagonally split for all cast metal frame motors.
Vendor’s standard fabricated steel terminal boxes for motors above 150 kW ratings may be acceptable with
SABIC approval.
5.8.2 Separate terminal boxes shall be provided for main leads and auxiliary devices, for example space
heaters, RTD’s, and vibration and brush monitoring device leads.
5.8.3 Boxes shall be of weathertight or special construction, as required for classified locations. Terminal
boxes shall be provided with threaded conduit openings or hubs on all motors.
5.8.4 Motor terminal boxes shall be rotatable for connection from any one of four directions at 90°
intervals.
5.8.5 Unless otherwise specified, terminal boxes on the horizontal motors shall be located on the right
hand side when viewed from the end opposite the shaft extension.
5.8.6 A motor lead seal and separator gasket shall be provided between the motor frame and terminal box
on all motors.
5.9 Motor Leads
5.9.1 Motor leads shall have the same class insulation as the windings, and shall be fitted with
manufacturer’s standard terminals. Leads and terminals shall be permanently marked in accordance with
NEMA MG-1.
5.9.2 If bus bar leads are used in the terminal box, to accommodate connections of the power supply
leads, the bus bars shall be fully insulated and supported.
5.9.3 The motor connection diagram shall be attached to the motor, either inside the terminal box or on the
motor frame on the same side as terminal box.
5.10 Auxiliary Cooling Fans
5.10.1 Fan motors shall be supplied in accordance with SES E06-S01.
5.10.2 Fan motors shall be rated 460 V, three-phase, 60 Hz, ac power supply.
5.10.3 The fan shall be of nonsparking, corrosion-resistant metallic material.
5.10.4 Fans shall have an air pressure switch to indicate loss of air flow.
5.10.5 Fan motors shall be interlocked with the dc motor, to ensure that the fan is running prior to starting
the dc motor.
5.11 Space Heaters
5.11.1 Sheath type heaters shall be provided, to prevent condensation when motors are idle.
5.11.2 The sheath temperature of space heaters when operating at site conditions and at 110 percent of
rated voltage shall not exceed 180 °C.
5.11.3 The space heaters shall be rated at 230 V, but shall be operated at 115 V, single phase service. The
heaters shall be energized through the motor controller on motor shutdown.
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DATE APR 2001
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5.12 Provisions for Grounding


5.12.1 Motors shall be provided with a visible, external tapped hole or lug in the frame foot located at the
end opposite the drive shaft and on the terminal box side of the motor, for attaching the grounding
conductor lug.
5.12.2 For motors rated above 150 kW, all non welded parts of the motor assembly and accessories shall
be bonded together with copper straps, and connected to motor grounding pad or grounding lug.
5.12.3 Motor terminal boxes shall be provided with a grounding lug inside the box.
5.13 Conduit and Wiring
All power and control wiring within the confines of the motor assembly and accessories shall be heat,
moisture, and abrasion resistant. All conduits shall be rigid galvanized steel (RGS) except for the areas
subject to vibration, where liquid-tight conduits with UL approved fittings shall be used. All leads from
alarm, auxiliary and control devices shall be brought out to terminal boards in the auxiliary terminal box.

6. Mechanical Design Features


6.1 Hazardous Areas
6.1.1 Motors shall comply with the requirements of NFPA 70 for hazardous classified locations. If vendor
does not receive complete area classification information (Class, Division, Group, and auto ignition
temperature) with the inquiry or purchase order, they shall contact SABIC to obtain this information.
6.1.2 Explosion proof and dust ignition proof motors shall bear labels by UL, or shall be labeled in
accordance with requirements of other SABIC approved certifying laboratories or authorities for proper
class(es) and group(s), and shall have a suitable temperature designation. Explosion proof motors shall be
furnished if they are available in the required rating. If an explosion proof motor is not available, the motors
shall be made safe for the area, using one of the methods allowed by NFPA 70.
6.2 Motor Enclosures
6.2.1 Motors shall be suitable for operation in severe environments associated with refineries and
chemical plants. Motor enclosures, accessories and internal components shall be protected to resist
chemicals, corrosion, moisture, and abrasives, for example particles, blowing sand and salt laden
atmosphere.
6.2.2 Motor frames shall be cast iron, rolled steel, or laminated steel construction.
6.2.3 Enclosures shall be as specified in SES E06-X04 in accordance with the following:
a. For hazardous areas, motors shall be totally enclosed explosion proof or totally enclosed pipe
ventilated. All accessories attached to motors shall be approved for installation in the classified
locations.
b. For non-classified locations, the motors shall be totally enclosed air-over piggyback (TEAOP) for
motors rated 150 kW and below. For motors larger than 150 kW the motors shall be totally enclosed
dual-cooled with air-to-air heat exchanger (TEDC-A/A) or totally enclosed dual-cooled with
air-to-water heat exchanger (TEDC-A/W). No free exchange of air shall occur between the inside and
outside of motor.
6.2.4 TEDC-A/A motors shall be furnished with stainless steel exchanger tubes. Separate ac motor driven
blowers shall be used for circulating internal and external air through the exchanger.
6.2.5 TEAOP and TEDC-A/A motors shall be provided with reusable stainless steel air filters. Filters shall
be securely fastened in place and easily removable for cleaning during motor operation. Filters shall be
provided with a differential pressure gage and alarm to indicate a dirty filter.
6.2.6 TEDC-A/W motors shall have exchangers with removable tube bundles. These exchangers shall be
fabricated with double tubes and flanges for in-plant cooling water. If a TEDC-AW enclosure is specified,
plant cooling water data will be given in SES E06-X04. Exchanger tubes shall be 90-10 Cu-Ni. Vendor
shall indicate in proposal the delta temperature and pressure across the exchanger, plus the required flow
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DATE APR 2001
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rate. Flow-sensing devices shall be provided in the water supply piping, to sense low and high flow, and
inner tube leakage.
6.2.7 TEDC-A/A and TEDC-A/W motors shall be supplied with two (2), 100 Ω, platinum RTD’s for input and
output air temperatures.
6.2.8 Motor shall have a corrosion resistant drain and plug in low point of the enclosure, accessible from
the exterior of the motor. Seals and slingers shall be provided to prevent moisture from entering through
the shaft opening.
6.2.9 Cast iron fan shrouds shall be supplied on cast iron frame for totally enclosed motors.
6.2.10 Motors shall be provided with eyebolt(s) or lifting lug(s).
6.2.11 Motors shall be equipped with stainless steel hardware. Hardware and threaded openings shall
conform to ANSI B1.1.
6.2.12 Vertical jacking bolts shall be provided on motors 55 kW and larger.
6.3 Bearings and Lubrication
6.3.1 Motors shall be furnished with grease-lubricated, anti-friction ball bearings, unless otherwise
approved by SABIC. Sealed prelubricated bearings shall not be acceptable.
6.3.2 Motors shall have noncontact labyrinth or taconite dust-resistant shaft seals.
6.3.3 Grease-lubricated bearing shall be supplied with two (2) threaded ports. The grease supply ports
shall have hydraulic fittings and shall be accessible from the exterior of the motor. The hydraulic grease
fittings shall be industry standard design. Grease drain ports shall be supplied with pressure relief fittings.
6.3.4 Anti-friction bearings shall be designed for a minimum L10 life of 40,000 hours under continuous duty
at rated load and speed, calculated in accordance with AFBMA Standard 9 for ball bearings or AFBMA
Standard 11 for roller bearings.
6.3.5 The lower section of each bearing shall be provided with two (2), 100 Ω, platinum RTD’s, on motors
rated 750 kW and above. The RTD’s shall be three (3) wire type.
6.3.6 Motors rated 750 kW and above shall be provided with both bearings electrically insulated. Insulation
resistance from the frame shall not be less than one (1) MW. Warning nameplates reading ‘Insulated
Bearing’ shall be provided. Provisions shall be included to permit direct resistance measurements on the
bearing insulation.
6.4 Shafts
6.4.1 Direction of shaft rotation shall be counterclockwise when viewed from the non-drive end, unless
otherwise specified by the engineered equipment vendor.
6.4.2 Shafts shall be in accordance with NEMA MG-1 standard dimensions for NEMA frame motors.
Shafts on horizontal motors shall be suitable for direct coupling, belt drive, or chain, as specified in
SES E06-X04.
6.4.3 Shafts shall be complete with the motor half coupling factory mounted, when specified in
SES E06-X04.
6.4.4 Shaft runout shall not exceed 0.050 mm for horizontal, and 0.025 mm for vertical motors.
6.4.5 Vertical motors shall have flanges similar to ‘P’ base, and shall have solid shafts.
6.4.6 Motors rated 750 kW and above shall have motor shaft position (magnetic center) and rotor end play
limits permanently scribed on the shaft. A permanent reference point shall be provided on bearing housing.
6.4.7 Vendor shall provide data to packaged equipment vendor as required, for torsional analysis.
6.5 Balancing and Vibration
6.5.1 Motor armature shall be precision balanced, see 5.5.1. The use of solder or similar deposits for
balancing shall not be acceptable. Parent metal removed to achieve dynamic or static balance shall be
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drilled out in a manner that does not affect the structural strength or electrical balance of the rotating
element.
6.5.2 The maximum amplitude (peak-to-peak) of motor vibration as measured at the bearing housing, and
the method of measurement, shall be in accordance with NEMA MG-1.
6.5.3 If specified in SES E06-X04, each bearing shall be provided with two (2) vibration probes and
oscillator demodulators. The probes shall be Bentley Nevada, Model No. 3300 series or SABIC approved
equal, displaced 90° apart and 45° from the vertical at each bearing.
6.6 Mounting
6.6.1 Motors shall be suitable for horizontal or vertical mounting as specified in SES E06-X04. If vertical
mounted motor is specified, packaged equipment vendor shall specify duty and thrust requirements in
SES E06-X04.
6.6.2 Type of motor mounting shall be as specified in SES E06-X04.
6.7 Noise Level
6.7.1 Noise level shall be in accordance with SES S20-G01. Motors shall not exceed a test stand (in
anechoic chamber) averaged noise level of 85 dBA at a distance of 1 m.
6.7.2 Vendor shall furnish noise level test data and a specific description of the acoustic treatment
provided for each motor on the noise control data sheet submitted with proposal.

7. Nameplates
7.1 Motor Nameplate
Motor nameplates shall be stainless steel and contain all information specified by MG 1, plus the following
additional data:
a. Bearing numbers
b. Vendor’s shop order
c. Serial number
d. Maximum ambient temperature
e. Equipment tag number
7.2 Accessory Tags
Accessories attached to the motor or shipped loose, shall be tagged with SABIC’s equipment item number.
Tags shall be corrosion resistant metal, and impression stamped ‘Item No. ________.’ The tags shall be
attached with stainless steel wire or fasteners.

8. Test and Inspection


8.1 All equipment and components shall be subject to inspection by SABIC. Any work or materials
rejected by SABIC shall be repaired or replaced. Repair procedures shall be subject to SABIC’s
approval.
8.2 All motors shall receive routine tests in accordance with NEMA MG-1 and IEEE 113 and 304.
Vendor’s proposal shall provide a complete listing of all routine production tests. Tests shall determine
that the motor is free of defects and meets the requirements of this specification.
8.3 Any additional tests shown in SES E06-X04 shall also be performed.
8.4 Vendor shall notify SABIC 2 weeks prior to final testing. SABIC reserves the right to witness all
tests.
8.5 Certified test reports shall be furnished in accordance with the purchase order.
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8.6 All material and workmanship shall be subject to inspection and testing after delivery to the site. If
any component is found to be defective in material or workmanship or otherwise not in conformance
with this specification, SABIC shall have the right to reject the motor or require corrective action.

9. Finish
9.1 External and internal surfaces (except machine parts) shall be cleaned and primed with a rust inhibiting
paint.
9.2 The interior of the motor shall be coated with corrosion and weather resistant paint.
9.3 The exterior of the motor shall be coated with an abrasion resistant, light reflective, heat reflective and
weather resistant paint.
9.4 The preparation and paints shall be in accordance with SES Q01-G02.

10. Documentation
10.1 Drawings
10.1.1 Drawing and data shall be provided with the proposal and during the design and manufacturing
stages. SABIC will review and comment on all drawings and data submitted for design review until such
time as the final documents are reviewed without comment.
10.1.2 The following drawings and data shall be required for evaluation at the proposal stage
a. Descriptive bulletins of motors offered in proposal
b. Dimensional outlines, plans and elevations with weights
c. Complete motor data including all ratings, frame number, enclosure type, ‘T’ number as defined
in NEC, guaranteed efficiency, and noise level data
10.1.3 The following drawings and data shall be required for approval:
a. Re-submittal of all drawings and data listed in Section 10.1.2
b. Complete nameplate data
c. Wiring diagrams
d. Conduit and cable entrances
e. Acceleration time, withstand time at locked rotor, and all torque values
f. Space heater voltage, number of phases and watts
g. Bearing details with AFBMA numbers, when applicable
h. Nameplate details for heat exchanger, as applicable
i. Specification and descriptive/technical bulletins for all accessories
10.1.4 The following documents are required at the time of shipping:
a. Complete parts list or equipment summary
b. Operating and maintenance instructions with stator rewind data
c. Price list of recommended spare parts
d. Certified test reports
10.2 Operation and Maintenance Manual
10.2.1 Vendor shall provide 3 copies of the motor operation and maintenance manual, which will become
an integral part of SABIC’s operation and maintenance manual for the project.
10.2.2 The manual shall include the following information:
a. Procedures for unloading and storage. Storage may be outdoor or indoor for extended periods.
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b. Installation instructions, including pre-operative inspections and check out of lubrication system,
cooling system (if applicable) and all protective devices supplied by the motor manufacturer
c. Operating instructions and troubleshooting charts, with corrective recommendations
d. Cleaning instructions for removal of protective coatings applied as part of the shipping
requirements
e. Selective drawings, for example wiring diagrams, locations of SABIC’s conduit and cable entries,
and motor outlines with weights and dimensions
f. Instructions for rotor removal, bearing removal and replacement, and data for rewind

11. Preparation for Shipment


11.1 All components shall be adequately marked to facilitate field installation. Boxes and crates shall be
marked with the project number, and item number, or as required by the purchase order, and shall have a
packing list enclosed showing the parts therein.
11.2 Prior to shipping, the motor shall be thoroughly cleaned, and paint damage shall be repaired. All
openings shall be covered with bolted-on metal plates and threaded openings, and threaded studs shall
be protected with steel plugs and caps.
11.3 Rust preventative shall be applied to all unpainted metal surfaces.
11.4 The exposed metal shaft shall be coated with a heavy grease to prevent rusting.
11.5 Should it be necessary for the terminal box to be removed and shipped as a separate package, the
motor leads shall be coiled and protected from damage.

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