THE ISRAEL ELECTRIC CORPORATION LTD. GENERATION DIVISION SPECIFICATION GD1/16

Transcription

1 . POWER STATION HIGH-VOLTAGE MOTOR REWINDING INDUCED DRAFT FAN MOTOR RUTENBERG 3-4 Prepared by: Checked by: Approved by: Relu ILIE Igor GOBENKO December 2016

2 1. Purchaser The Israel Electric Corporation Ltd. (IECo) - Israel. 2. Name Of Item / Project Full rewinding of induced draft fan motor Rutenberg Location Of Item / Project The motor covered by this specification is located in Purchaser s power station or storage. 4. Scope The scope of work covered by this specification is full rewinding of induced draft fan motor stator, located in Rutenberg 3-4 power station. Based on results of tests from Item 11.1 and motor history, the scope of work shall be in details defined between Purchaser and Contractor Project Description N/A 4.2. Scope Of Supply The motor name plate rated data for the specific motor to be repaired are as following. The single line diagram is attached to this specification. IECo will decide if the motor to be repaired is originally made either by KONČAR Croatia, respectively by ABB Switzerland as detailed below Phases: Frequency: 50 Hz Rated voltage: V Rated speed: 746 rpm Insulation Class: F Rating: 6125 kw Rated current: 314 A Power factor: Connection of stator winding: star Original manufacturer: KONČAR Croatia, respectively ABB Switzerland Type: 6AJZ0a 900L1-8, respectively ONG 900 fa Serial number: 23358, respectively HM Protection: IP 55, respectively W24. The scope of work shall include at least the following (but not only): Stator core flux test (including thermographic test), after removing the old coils and after installing the new coils Full rewinding, which shall include dedicated turn insulation (in addition to strand insulation) End-winding support hardware repair or replacement (if necessary) Replacement of motor heaters 2

3 Renovation or replacement of motor main terminals. It shall include suitable protection for overvoltage originated by vacuum circuit breakers (surge arresters and capacitors) The neutral point of stator windings shall be externally accessible and shall allow dismantling in order to permit each phase separate insulation testing Replacement of support isolators Cleaning and painting the motor and motor leads box (first layer epoxy and second layer polyurethane RAL 1023) Replacement of the bearings (IECo will supply the bearings) Replacement of the RTD's Rotor check and repair (if necessary) Rotor balance, if repaired Check, test and adjustment of accessories (e.g. cable entries, earthing bolts, terminal boxes, terminal marking, enclosure, nameplate labels, lubrication, fans, thermal monitors, coolers etc.). 5. Terminal Points &Terminal Connections N/A 6. Cyber & Information Security N/A 7. Quality Assurance & Quality Control 7.1. General Quality Requirements To be checked by Purchaser's Quality Control representative. The manufacturing and all components shall confirm to quality requirements and shall ensure high reliability. The Bidder shall submit with his proposal copies of quality assurance and quality control procedures. The Bidder shall provide a full I&T plan with references to his shop specifications, standards used, and acceptance criteria. The acceptance tests (paragraph 11.2) shall be performed in the factory, in presence of Purchaser s Quality Control representative. The purchaser reserves the right to send a representative to attend part or all of the acceptance tests. The contractor shall include in its technical offer a test plan (appendix A), which will include at least all of the tests according to this specification (paragraph acceptance test), including tentative time schedule. The contractor shall announce the updated time schedule, immediately after receiving the order and shall update it if necessary. The Contractor shall notify IECo by a non-conformance report in any case or process a problem occurs, for any component which is out of specification, for any component testing if a failure occurs Interchangeability 3

4 The repaired motor shall provide the same or better parameters, characteristics and performance, from all points of view, as the motor before repairing. 8. Standards & Codes In principle, the required tests procedure shall conform to IEC relevant standards (mainly IEC series). For tests not covered by IEC standards, ANSI, IEEE, NEMA, VDE standards shall be applied, or the normal Purchaser internal practice. 9. Technical Documentation 9.1. General N/A 9.2. Technical Documentation Attached to Proposal The Bidder shall supply to Purchaser the guarantee values of motor relevant data that will be achieved after the repair. The tolerances for guarantee values shall be according to IEC Technical Documentation to Deliver after Award Notification The Contractor shall provide with the repaired or overhauled motor all data and drawings showing the details of the work performed (i.e. active core dimensions, slot details, insulation material type, cross section of coils, rated power if changed, losses if influenced by repair, etc.). If applicable, these data shall be presented comparatively with the condition before repair. In addition, the Contractor shall supply type and routine test reports and operation and maintenance manual (if relevant). 10. Technical Requirements Environmental Considerations & Service Conditions The altitude of the power station does not exceed 1000 m above the sea level. The motor shall be outdoor mounted. The expected ambient air temperatures are: - Maximum momentary C - Minimum momentary C - Monthly average of the hottest month C - Yearly average C The motor is expected to be exposed to long dry periods without rain, sometimes with very fine sand dust, changing suddenly to periods of high humidity and rain. The motor might also be exposed to a moderate combination of conductive or abrasive dust (such as coal dust, fly ash, etc.), sulfur smokes,moisture, etc., as encountered in usual power plant applications. The motor at seashore location is expected to be additionally exposed to coastal conditions with salt laden spray and storms. 4

5 The motor might be exposed during summer days to very intensive solar radiation Reliability, Availability, Maintainability (RAM) The repair performed shall be intended to improve the reliability and availability of the motor Functional Requirements The stator winding insulation shall be of Class F or Class H, but the temperature rise shall correspond to Class B conditions The insulation system of stator winding shall be Vacuum Pressure Impregnated (VPI). If approved by IECo, resin rich insulation system can be used, assuring a similar winding quality, reliability and operation life as VPI The Contractor shall use wires with at least the same cross section as the existing one in the motor If applicable for repairing work, the rotor squirrel cage shall be made of copper or copper-alloy bars The minimum monitoring devices (RTD's, thermocouples, etc.) shall be of the same type and quantity as in the motor before the repair / overhaul. 11. Tests & Inspections Motor Test Before Repair The motor shall be dismantled and tested in presence of Purchaser's representative. The Contractor shall send to the Purchaser an initial detail report of the condition of the motor At least the following tests shall be performed: Visual inspection of stator and rotor Air gap clearance measurement Measurement of insulation resistance of stator winding, at 5000 V DC Measurement of stator winding resistance Acceptance Tests 5

6 The Purchaser has the right to witness any process or tests performed in the Contractor's facilities without any additional price. The witnessing will be performed in such way to avoid any impact on the contractual repair or overhaul schedule/delivery time The tests and acceptance conditions detailed in the items below shall be completed. Additional tests and additional/changed acceptance values can be agreed between Purchaser and Contractor Factory tests shall be performed for each coil before install, e.g.: Strand strand isolation check Insulation resistance & PI DC Ramp Dissipation Factor and Tip-Up Partial Discharge Final Hi-Pot These tests shall all have acceptance criteria spelled out in advance and reports shall be supplied for each coil The following tests shall be performed on 2 sample coils: Voltage Endurance Surge test (IEC ) Hi-Pot to Breakdown Dissection A full report on these tests shall be provided The following tests shall be performed on the repaired motor in the factory, in presence of Purchaser s representative: Measurement of stator winding resistance, each phase separately (the winding neutral point is accessible by ). For acceptance, each measurement shall not differ from each other by more than 2% Measurement of stator insulation resistance and polarization index, each phase separately (the winding neutral point is accessible by ), at 5000 V DC. The minimum acceptance value of insulation resistance at 40 C shall be 300 MΩ. The minimum acceptance value of polarization index shall be Measurement of insulation resistance of heaters, thermometers, thermocouples, thermistors, thermostats, etc. used for windings, bearings or cooling circuits at 500V DC, 1 min Measurement of no-load current (including current symmetry) and losses at rated voltage and frequency. 6

7 The no-load running shall be performed for about 1 3 hours, until thermal equilibrium is achieved. The no-load currents unbalance shall not exceed 20% Check of direction of rotation versus phase sequence and mark it on the wires and the motor. The phase sequence in the connection box shall be kept as it was before starting the work Measurement of mechanical vibrations for housing and attachments, performance of noise assessment. Maximum acceptable values according to ISO : r.m.s. velocity 2.3 mm/s, radial and axial direction, at bearing housing Behavior of bearings (lubricant level, temperature, noise, vibrations) On motors supplied with insulation bearings, measurement of bearing insulation resistance at 500V DC, 1 min. and measurement of shaft voltage Measurement of locked-rotor torque and current (including current symmetry) at rated current times service factor, rated frequency and reduced voltage. The short-circuit currents unbalance shall not exceed 5% Performing of moisture withstand test for sealed stator winding (water immersion or spray test) according to NEMA MG1. The Contractor shall announce to the purchaser at which method he will perform the test (either submerge or spraying), in the technical stage Measurement of dielectric dissipation factor (tgδ) with different applied voltages, up to rated voltage, each phase separately. The maximum acceptance value of tgδ shall be 2% (at 20 C 30 C). The maximum acceptance change in tgδ value from 20% of rated voltage to rated voltage shall be 50% Partial discharge measurements of stator with voltages up to rated voltage, each phase separately Power frequency withstand test of the stator winding with voltage (2UN + 1) kv for 1 min, each phase separately Impulse withstand test of main insulation of 2 individual sample coils with peak voltage of 4UN + 5 kv (1.2/50µs). 7

8 11.3. Field Tests Impulse test (inter-turn insulation) withstand test of 2 sample coils with peak voltage of 0.65 x (4UN + 5) kv having a front time of 0.2 µs Air gap clearance measurement. As acceptance condition, the difference between the measurements at diametrical opposite air gap points shall be less than 5% from air gap average clearance Rotor tests analyses of stator current harmonics by Motor Monitoring or similar method (if applicable for repairing work) Over-speed test for rotor if repaired, at 120% rated speed. In addition, rotor dynamic balancing test, if repaired Check, test and adjustment of accessories (e.g. cable entries, earthing bolts, terminal boxes, terminal marking, enclosure, nameplate labels, lubrication, fans, thermal monitors, coolers etc.) Direct rated voltage starting test, including measurement of starting currents and starting time and successive starts test according to motor design. This test can be performed also in Contractor or Purchaser s facilities under Contractor responsibility. Acceptable locked rotor current is until +20% of rated value The Purchaser shall have the right to perform all or a part of the following field tests, on motor mounted in power station, before the first operation following the repair: Check of direction of rotation versus phase sequence Measurement of no-load current and losses (with the load uncoupled) Measurement of mechanical vibration Measurement of insulation resistance and polarization index at the same DC voltage as in Items , Measurement of partial discharge with voltage up to nominal voltage. 8

9 12. Packaging & Delivery Power frequency withstand test of stator winding at 0.80 x (2UN +1) kv Tgδ measurement according to item Measurement of bearing insulation resistance on motors supplied with insulated bearings Rotor tests analyses of stator current harmonics by Motor Monitoring according to item Check of the accessories Direct rated voltage starting test, including measurement of starting currents and starting time according to item The repair or overhaul shall be performed in Contractor s factory. The transportation to and from the Contractor s factory, including the insurance, shall be the Contractor s responsibility (as an integral part of the contractual repair or overhaul schedule/delivery time) unless otherwise agree. 13. Storage & Handling The Contractor shall submit instructions for long term motor storage. 14. Nameplate & Marking The contractor shall renew the nameplate, include IECo motor number. The contractor shall mark the motor phases. 15. Notes Within this specification, the word "shall" indicates mandatory requirements, from which no deviation is permitted. The word "should" indicates a preferred or recommended possibility. IECo keeps its rights to qualify or disqualify any Bidder following the fulfilling of any specification requirement. All deviations from this specification shall be separately listed. In the absence of such list, it will be presumed that the provision of the specification are complied with by the Bidder. (See also non-conformance reporting requirement in item 7.1 above). 16. Special Requirements Warranty The warranty period of the repaired motor shall be at least 12 months from first operation Repair Duration 9

10 The works detailed above (scope of work and tests) shall be performed in the Contractor facilities during 60 calendar days or less Threshold Conditions The Contractor shall provide with the proposal a reference list showing his proven experience performing rewinding of similar motors (rated power, voltage) - at least 2 similar motors in the last five years The Bidder shall include in his technical proposal ISO-9001 qualification certificate or similar Others The repair or overhaul shall be performed in Contractor s factory The Contractor shall issue a Root Cause Analysis of the original failed motor The Contractor shall issue an acceptance test report, before shipment The Contractor shall issue a final report, within 30 days after completion of the scope of work All documentation shall be issued in English or Hebrew. 10

11 Appendix A TEST PLAN CONTRACTOR`S: NAME, I&T PLAN TITLE, THE PRODUCT INSPECTED/TESTED, AND DOCUMENT IDENTITY & APPROVAL. PURCHASER`S : NAME AND PROJECT`S NAME AND LOCATION NO. THE INSPECTI ON OR TEST APPLICABL E DOCUMENT S WP/HP OR OTHER SUB- CONT./ SUPPLYE R INSPECTED/TESTED BY : CONTR- ACTOR PURCH- ASER OTHER TIME SCHEDULE REMAR KS 11

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