TECHNICAL BULLETIN

Release No.: TB-099 Date: 20-Nov-2023

SA-MOC-23-0131

560 SERIES PLUG-IN MOTOR LEAD IMPROVEMENT

INTRODUCTION

Plug-in Motor Lead Extension (MLE) was introduced by APC in 2019. This represented a step forward in reliability
but also a product feature to reduce field installation risk by eliminating the MLE to motor terminal splice inherent to
Tape-in design.

Latin America Region was the early adopter of the technology, partly to address failures of the Tape-in MLE that
some clients were suffering, particularly at high temperatures. Survivability trends have been very positive to the
point that Latin America has standardized to Plug-in MLE technology for all the motors installed in their operations.

DESIGN EVOLUTION

As part of continuous improvement, a design evolution of the 560 plug-in pothead was released to facilitate assembly
in the manufacturing center and make the design more robust.

A cross section comparison between the initial release and the new design is detailed in figure 1.

Figure 1.
(Left) Initial released design for 560 plug-in MLE (V1)
(Right) New released design for 560 plug-in MLE (V2)

The new design features the following improvements:

1. A one piece insulating block (in green – Figure 1 (right)) that replaces back and front insulating blocks
in the initial design (in orange – Figure 1 (left)), thereby increasing the distance of path to ground and in
between phases on the back side of the insulating block.

2. More space for layers of insulating tape during manufacturing of the MLE, increasing dielectric strength
and robustness.

3. Extended taping coverage beyond pothead flange back end for increased mechanical and electrical
protection.

4. Larger phase-to-phase distance due to increase in base circle diameter.

Prepared by: Reviewed by: Approved by:

J. Caridad Mechanical Engineering Director Global QHSE Director
This document contains information proprietary to Alkhorayef Petroleum intended solely for the controlled use of Alkhorayef employees.
The contents are not to be reproduced or disclosed without prior written authorization. © Alkhorayef 2023

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 TECHNICAL BULLETIN
Release No.: TB-099 Date: 20-Nov-2023
SA-MOC-23-0131

VALIDATION AND VERIFICATION

Samples of the new design were built in DMC to prove out manufacturability as well as to subject the prototypes to
the standard factory acceptance tests, including pressure test and hi-pot test. All these activities were conducted
successfully, and incorporated in the assembly procedure (MPP).

Additionally, the new prototypes (V2) along with a sample of the initial design (V1) were tested to failure (AC
breakdown test - ACBD) to confirm that the new design represented an improvement over the incumbent. Details
on the test set-up and device under test are shown in Figure 2.

Figure 2.
(Left) ACBD Test set-up, including hi-pot device and Device Under Test
(Right) Detail of 3-ft MLE Device Under Test

AC breakdown results were very positive for the new design, with very consistent failure voltages in excess of 25kV
on all leads tested, representing a substantial improvement over the previous design.

Prepared by: Reviewed by: Approved by:

J. Caridad Mechanical Engineering Director Global QHSE Director
This document contains information proprietary to Alkhorayef Petroleum intended solely for the controlled use of Alkhorayef employees.
The contents are not to be reproduced or disclosed without prior written authorization. © Alkhorayef 2023

Page 2 of 3
 TECHNICAL BULLETIN
Release No.: TB-099 Date: 20-Nov-2023
SA-MOC-23-0131

INTRODUCTION TO THE FIELD AND COMPATIBILITY

To the naked eye, both designs are indistinguishable, however, there are dimensional differences that make them
non compatible.

As a result, a differentiator in description (V2) was added on the Part Numbers using the new design. A V2 will also
be marked on the pothead during manufacturing to facilitate identification in the field. Because of these dimensional
differences, the insulating block in the motor also requires modification, and motors that can accept V2 MLEs also
have V2 in their description. In other words:

1. V2 MLEs are only compatible with V2 motors.

2. Previous design MLEs (i.e. without V2 in description) are only compatible with previous design motors
(i.e. without V2 in description).

3. Mixing of previous design MLEs (i.e. without V2 in description) with V2 motors, or V2 MLEs with
previous design motors (i.e. without V2 in description) will result in service quality incidents because
dimensions are not compatible.

Because of the expected improvements in reliability of the new design, all motors and MLEs with original design
will be made unpurchaseable, and plug in technology (MLE and motors) will be standardized to the V2 version.

For any 560 motor or MLE orders to be placed to DMC effective from November 2023, new part numbers need to
be requested via the new part number portal in Sharepoint (Data Master Control - Home (sharepoint.com).
For inventory related to the previous design available at locations, it can be consumed until depletion.

Prepared by: Reviewed by: Approved by:

J. Caridad Mechanical Engineering Director Global QHSE Director
This document contains information proprietary to Alkhorayef Petroleum intended solely for the controlled use of Alkhorayef employees.
The contents are not to be reproduced or disclosed without prior written authorization. © Alkhorayef 2023

Page 3 of 3