Method of Statement For Motors
Method of Statement For Motors
Federation
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Engineering Contractor:
Review:
Construction Contractor:
PROJECT
CONTRACT NO
DOCUMENT TITLE
DOCUMENT NUMBER
DOCUMENT
Status
DESCRIPTION
Status
- PRC
Revieved
Engineer:
NAME
Remarks or Comments:
REV.
A1
Code
- QA
DATE
A1
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Rev.
Amendment
Prepared
Checked
Approved
Date
Company:
Engineering Contractor:
Construction Contractor:
Project Title:
Document Title:
METHOD STATEMENT
FOR
MOTORS
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REVISION SHEET
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Description of changes
First Issued For approval
Page
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Contents
1. PURPOSE 5
2. SCOPE......5
3. DEFINITIONS
4. RESPONSIBILITIES...6
5. PREREQUISITES and PRECAUTIONS....6
6. PROCEDURES...8
7. ACCEPTANCE CRITERIA...12
8. ATTACHMENTS.......13
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1. Purpose
This procedure provides a safe, standardized approach for the initial inspection, checkout,
testing, and data documentation of electric motors used to drive rotating equipment.
2. Scope
This procedure is applicable to the RSAE project Site and covers all motors. It applies to
AC MV and AC LV motor used to drive rotating mechanical equipment. Motors used as
operators for valves, gates, dampers, etc. are not within the scope of this procedure.
This procedure shall be implemented during initial uncoupled/unloaded operation of
applicable equipment, as well as during the initial coupled/loaded operation. However, it
may be used at any time during equipment operation.
3. Definitions
Project
: Gazprom Neftehim Salavat Acrylic / Acid Plant
Company
: Gazprom Neftehim Salavat
Construction
: Renaissance Construction (RC)
Supplier (Manufacturer/Vendor) : The supplier (Manufacturer/Vendor) is the party
that manufacturers or supplies equipment and services to perform the duties specified by
the Company or Contractor.
The word SHALL indicate a requirement.
The word SHOULD indicate recommendation.
Drive End (DE) - The end of the motor from which the shaft protrudes and is coupled to
the driven equipment. It may also be referred to as the inboard (IB) end of the motor.
Non Drive End (NDE) - The end of the motor that is opposite the DE. This end of the
motor usually has the motors cooling fan attached. It may also be referred to as the
opposite drive end (ODE) or outboard (OB) end of the motor.
Bump - To start and immediately stop a motor from a Local Control Switch or temporary
remote signal instead of DCS signal to verify direction of rotation.
Rotation - The rotation of a motor as viewed from behind the NDE, standing with line of
sight in-line with the rotor, looking toward the drive shaft of the driven equipment.
Magnetic Center - That position of Sleeve bearing type motor rotor where the magnetic
forces acting on the rotor are in balance during operation. In large motors during initial
run-in, the magnetic center is marked to allow positioning of the rotor at the magnetic
center for coupling alignment. Placement of the rotor at the magnetic center assures that
no thrust from the motor is transmitted to the driven equipment via the coupling.
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Motor Doweling - A practice on some large motors where the motor base is drilled and
dowels inserted to prevent movement of the motor. This is usually done to permanently
fix the final alignment position of the motor. In some cases the driven equipment may
also be doweled in place.
4.
Responsibilities
4.1
Prerequisites
5.1.2 Verify that test equipment used for recording data are calibrated within their
calibration interval and document on the Motor Data Record. Temporary barricade not to
access the unauthorized person shall be provided around inspected motor before motor
operation
5.1.3 Verify that the equipment is correct (per data sheets, specifications, etc.) and
installed in accordance with project design documents and vendor manuals/drawings.
Also verify that the system installation is complete to the extent necessary to properly
support equipment operation. Review system/component punch list.
5.1.4 Review the vendors instruction manual(s) for special precautions or limitations
specific to the equipment/systems components. Note and observe the vendor's
precautions and limits, such as number of starts, run-in duration, vibration, load, etc.
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5.1.5 Verify that equipment lubrication is in accordance with the vendor's specifications,
and either a lubrication tag is attached or other documentation is verified.
5.1.6 Verify that protection systems, instrumentation, controls, and alarms associated
with the equipment under test are tested, calibrated, functional, and documented to the
extent necessary to support testing.
5.1.7 Verify that the motor bearing lubrication and cooling system, if any, is available
for operation. If applicable, also verify that auxiliary cooling fans have been checked out
and are available.
5.1.8 All LV and all MV Motors shall be uncoupled prior to initial start and run-in.
5.1.9 Verify that the motor supply breaker/switchgear has been functionally tested to
permit motor operation.
5.1.10 Ensure that motor filters are installed if applicable. Replace filters as required.
5.2 Precautions
5.2.1 Areas under test must be clean and free of loose debris and only authorized
personnel are permitted in test areas.
5.2.2 Systems (complete or partial) or equipment under initial test where high energy
will be introduced for the first time must be physically walked down to ensure
unauthorized personnel are removed from test areas. As required, personnel may be
stationed at designated locations to keep test areas free of unauthorized personnel.
Emergency egress routes must be identified and verified clear of obstructions.
5.2.3 Equipment Lock out / Tag out (LOTO) requirements in support of this activity
must be implemented
5.2.4 A pre-test briefing incorporating STARRT/JHA must be conducted. Discuss test
performance and expected results with involved personnel. Personal Protection
Equipment (PPE) identified in the STARRT/JHA is required to be worn during
performance of this test.
5.2.5 Special attention must be provided for protection of personnel and equipment.
Ensure precautions such as barriers, flagging, danger signs, horns, area restrictions, etc.,
are used to protect personnel and equipment.
NOTE: Special attention should be paid to areas parallel to rotating equipment shafts.
These zones are especially susceptible to debris launched tangentially from rotating
equipment during a failure.
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5.2.6 Immediately terminate testing if any unusual noises, smoke or anomalies occur, or
if design limits that may compromise the safety of personnel or equipment are exceeded.
Immediately notify the Lead Electrical Commissioning Engineer and the site HSE
representative (if applicable) of such occurrences.
5.2.7 Assure adequate access is provided to all required areas during the test. Where
permanent access is not provided, scaffolding or a man lift must be provided in
accordance with job site procedures.
5.2.8 Establish appropriate level of communication between test and HSE personnel.
5.2.9 Loose fitting clothing or long hair shall be properly secured to prevent
entanglement when working around moving equipment.
5.2.10 Rotating parts, such as couplings, pulleys, external fans, and unused shaft
extensions, should have permanent guards installed to prevent accidental contact with
hands or clothing. This is particularly important where the parts have surface irregularities
such as keys, keyways or setscrews.
5.2.11 Loose parts of the coupling that cannot be removed for the motor uncoupled run-in
shall be tied off or affixed in such a way that they shall not contact the motor shaft or any
other rotating part.
5.2.12 Equipment must not be operated unless its supervisory and protective devices are
calibrated, tested, and functional. No protective devices shall be de-rated or bypassed
unless temporary protection is provided.
6. Procedure
NOTE: The vendors instruction manual and vendor requirement takes precedence over
this procedure in the event of conflicts. Detailed equipment operation shall be according
to vendor manuals.
6.1 General
6.1.1 This test shall be performed concurrently with the Equipment Vibration Testing
Procedure. The Test Engineer will coordinate all activities as necessary.
6.1.2 Motor run-in time shall be as specified until bearing temperatures and winding
temperatures (as applicable) stabilize. A temperature is normally considered stable when
three successive readings taken at 10-minute intervals do not vary by more than 5
percent. A 4 hours run-in time shall be considered adequate for all motors with Motor
rated voltage: 380V AC.
6.1.3 During initial run-in, record those equipment parameters that have an accessible
indicator. Typical parameters that establish the motor's characteristics include bearing
temperatures, winding temperatures, lubrication flows and temperatures, etc. The data
should have a common time basis and be recorded at a specified interval. The following
are several acceptable recording methods:
Manual recording of local indicators/digital meter on MCC in
substation
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6.1.4 Use the Motor Data Record, to document test results and attach charts, graphs,
data printouts, etc. Data collection can be stopped when monitored parameters have
stabilized.
6.1.5 During the coupled run-in of variable or multi-speed equipment data should be
taken at:
Operational speed (60Hz)
NOTE: On variable speed equipment, particular attention should be exercised to
avoid operation at, or near, the equipment critical speed.
6.1.6 Temporary alterations installed during testing shall be recorded on Motor Data
Record. Temporary alterations that are to remain following completion of testing shall be
logged according to the requirements of the Control of Temporary Modifications
Procedure.
6.2 Inspection
6.2.1 Ensure that the motor is clean and dry. The motor and Tag plate shall be legible.
End bells, covers, filters, and accessories shall be firmly attached.
6.2.2 Record motor nameplate data on the Motor Data Record.
6.2.3 Verify that the voltage, phasing and the frequency of the motors power supply
agree with those on the motor nameplate and the appropriate drawings.
6.2.4 Verify that motor terminations are properly made up.
6.2.5 Verify that the motor is properly grounded in accordance with the project
grounding notes, symbols, and details. Standard drawing (3935 E206-00100)
6.2.6 Inspect collector rings and brushes. The collector rings shall be clean and free of
any mechanical damage. The brushes shall make good contact with the slip rings and the
brushes shall slide smoothly in their holders.
6.2.7 Verify that the motor protection circuits have been set.
Record the initial settings in the comment section of the Motor Data Record, Exhibit
1.6.2.8 Verify that all protective relays have been calibrated and functionally tested.
6.2.9 Inspect cable gland connections for instrument and power cables ensuring that
bushings are installed, tightly and cable protection cover (If necessary) are installed.
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6.5. Restoration
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6.5.1 Verify that temporary alterations made during the performance of this test have
been restored or controlled according to Control of To be submitted in case restoration is
required.
6.5.2 Verify that temporary test equipment has been removed, and all system
connections and permanent equipment are replaced and secured. Ensure terminal box
cover is tight and has appropriate gasket installed.
6.5.3 Verify that equipment and system(s) affected by this procedure are restored to
conditions as specified by the person responsible for the system(s).
6.5.4 Verify that applicable previous data records have been completed.
7. Acceptance Criteria
All equipment operating parameters including vibration, currents, voltages, resistances,
and temperatures shall be within project design and vendor requirements and tolerances.
The motor operation shall be generally smooth.
Refer to the vendors manual. Insulation Resistance (Megger) Testing are within project
design and vendor requirements. In some cases the motor may be run for an extended
period of time to dry out the motor and allow the insulation resistance to increase over
time.
8. Attachments
AMotor Run Testing Process Map
BMotor Run Testing Process Map (contd.)
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Attachment A
Test Engineer
NO
To Page
2
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Construction
Page:
Uncouple
motor from
driven
equipment.
If possible
Engineering
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Attachment B
From
Page 1
Place support
system in service
Is rotation
Correct?
NO
Swap leads to
correct
rotation and
update
markings
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