DOCUM EN T R EVI EW AN D COVER SHEET

Construction Contractor:

Com pany:

Engineering Contractor:

Engineering and Technical Services:

R eview :

PROJECT

Gazprom Neftekhim Salavat Acrylic Acid / Acrylates Plant

(RSAE) Project Bashkortostan, Russian Federation

CONTRACT NO

88621 - December, 2012

DOCUMENT TITLE

Motors

DOCUMENT NUMBER

RSAE

DOCUMENT DESCRIPTION

Method Statement

- MTS

QA

- EL

- 009

REV.

A1

Status

Status Code

APPROVED WITHOUT COMMENT

REVISE AND RESUBMIT. WORK MAY

INCORPORATON OF CHANGES INDICATED.

REJECTED. TO BE REVISED B: RESUBMITTED. WORK MAY NOT PROCEED

INFORMATION ONLY. REVIEW NOT REQUIRED. WORK MAY PROCEED

CANCELLED/SUPERSEDED

Revieved Engineer:

Code Description

NAME

SIGN

PROCEED

SUBJECT

TO

DATE

Remarks or Comments:

Docum ent N um ber:

R evision:

RSAE

MTS

QA

EL

009

PROJECT CODE

DOCUMENT TYPE

DEPARTMENT CODE

DICIPLINE CODE

SEQUENCE NUMBER

A1

REVISION SHEET
Revision Description of changes
A1

Page

First Issued For approval

Docum ent N um ber:

R evision:

RSAE

MTS

QA

EL

009

PROJECT CODE

DOCUMENT TYPE

DEPARTMENT CODE

DICIPLINE CODE

SEQUENCE NUMBER

A1

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
Issue Date:

19/09/2014

Doc. Number:

RSAE-MTS-QA-EL-009

Revision:

A1

Page:

1 of 14

Contents
1. PURPOSE ...............................................................................................................................................2
2. SCOPE.....2
3. DEFINITIONS .........................................................................................................................................2
4. RESPONSIBILITIES......3
5. PREREQUISITES and PRECAUTIONS4
6. PROCEDURES...................6
7. ACCEPTANCE CRITERIA..10
8. EXHIBITS ....10
9. ATTACHMENTS.......10

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
Issue Date:

19/09/2014

Doc. Number:

RSAE-MTS-QA-EL-009

Revision:

A1

Page:

2 of 14

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

RSAE project

AC MV and AC
LV motor

This procedure is applicable to the SALAVAT Project Site and covers all motors. It applies to ac and dc
motors 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
Local Control Switch or temporary remote signal
outboard (OB) end of the motor.

Bump - To start and immediately stop a motor from a control switch 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 the 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
Sleeve bearing type motor
coupling.

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.

instead of DCS signal

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
Issue Date:

4.

19/09/2014

Doc. Number:

RSAE-MTS-QA-EL-009

Revision:

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Page:

3 of 14

RESPONSIBILITIES
4.1

Test Program Manager

Has overall responsibility for test program and shall act as Test Program Manager.

4.2

Test Engineer
Has responsibility for detailed checkout and testing of electric motors and shall act as Test
Engineer. Coordinates with discipline engineers, operations, and test performers to accomplish
testing and completes the Motor Data Record, Exhibit 1. The Test Engineer performing this
procedure shall ultimately be responsible for all evolutions. Correct rotation of the Motor (in
relation to the driven equipment) must be verified by the Mechanical Commissioning Engineer.

4.3

Health, Safety and Environmental (HSE) Representative

Participates in and provides input to Safety Task Analysis Risk Reduction Talk (START)/Job
Hazard Analysis (JHA). Provides HSE coverage for test activities and walk downs.

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
Issue Date:

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Doc. Number:

RSAE-MTS-QA-EL-009

Revision:

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Page:

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5. PREREQUISITES AND PRECAUTIONS

5.1

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, Exhibit 1.
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.
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.

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
Issue Date:

5.2

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Doc. Number:

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Revision:

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Page:

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Precautions

5.2.1 Areas under test must be clean and free of loose debris and only authorized personnel are permitted
Temporary barricade not to access the unauthorized person shall be provided around
in test areas.
inspected motor before motor operation

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.
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 control room personnel.
HSE

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.

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
Issue Date:

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Doc. Number:

RSAE-MTS-QA-EL-009

Revision:

A1

Page:

6 of 14

and vendor requirement

6. Procedure

NOTE: The vendors instruction manual 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. Motor rated voltage :380V

6.1.2

Motor run-in time shall be as specified by OGK4 CSU 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 400 V ac or
125 V dc supplies.
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, cooling fluid 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:
The plant DCS or computer

6.1.3

6.1.4

6.1.5

6.1.6

A chart recorder

A data logger

Manual recording of local indicators digital meter on MCC in substation

Use the Motor Data Record, Exhibit 1, to document test results and attach charts, graphs,
data printouts, etc. Data collection can be stopped when monitored parameters have
stabilized.
During the coupled run-in of variable or multi-speed equipment data should be taken at:
Minimum (or low) speed.

Anticipated normal (or medium) speed.

Maximum (or high) speed.

Operational speed (60Hz)

NOTE: On variable speed equipment, particular attention should be exercised to

avoid operation at, or near, the equipment critical speed.
Temporary alterations installed during testing shall be recorded on Exhibit 1, 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.

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
Issue Date:

6.2

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and Tag plate

Inspection
6.2.1

Ensure that the motor is clean and dry. The motor nameplate 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, Exhibit 1.

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. On dual voltage motors ensure that
the connections are correct for the supplied voltage.

6.2.5

Verify that the motor is properly grounded in accordance with the project grounding notes,
symbols, and details.
standard drawing

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.
according to 3935 E331-00100,00200

6.2.7

Verify that the motor protection circuits have been set. If Engineering has not provided
initial settings the following may be used:

(3935 E206-00100)

Instantaneous trip (magnetic overloads or quick blow fuses) is the locked rotor (LR)
amperage if given on the name plate

Timed trip (thermal overloads or slow-blow fuses) is set at 1.05 FLA

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.
cable gland

6.2.9

instrument

Inspect conduit connections for control and power cables ensuring that bushings are
installed, conduit connections are tight and covers are installed.
tightly

6.3

cable protection cover

(If necessary)

Pre-Run Tests
6.3.1

The insulation of the motor windings and power cable should be meggered prior to the
initial run if not recently meggered.

6.3.2

The winding resistance and the applied voltage shall be measured phase to phase. earth

6.3.3

Support systems, such as lube oil or cooling water, shall be placed into operation.

6.3.4

The motor shaft shall be manually rotated (if possible) to ensure that the rotor moves
freely, without rubbing.

6.3.5

Phase rotation may be initially checked using a motor phase rotation meter for any motor.
However, an initial check by actual motor rotation (bump) is mandatory for motors and
because
driven equipment that might be damaged by reverse rotation:
a. Lock out / Tag out the motor supply breaker. Supply the Lockout/Tagout on breaker of
power supply

b. Connect the leads of the phase rotation meter to the motor terminals at the motor
terminal box or feeder (load) terminals for the motor at the starter or switchgear.

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
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RSAE-MTS-QA-EL-009

Revision:

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c. Slowly rotate the motor shaft (rotor) in the proper direction of rotation for the driven
equipment and verify that the phase sequence on the meter matches the phase sequence of
the line (supply) connections.
d. If the phase sequence indicated on the meter does not match the design (line) phase
sequence, interchange the motor leads of two phases at the motor terminal box or at the
starter or switchgear. motor internal wire
NOTE: If leads need to be swapped all labels, tags, markings, etc. need to be revised to
match issued drawings.
e. Recheck the phase sequence of the motor winding using steps b. and c. above and record
the sequence on the Motor Data Record, Exhibit 1.
f. Remove the Lock out / Tag out.
6.3.6

For a motor supplied from a load center or switchgear bus, place the breaker in the
operating position (racked-in). For a motor equipped with a starter and supplied from a
motor control center and/or distribution panel, place the breaker in the closed position.
Verify that the motor space heaters, if supplied, are energized and note their operation in
the comment section of the Motor Data Record, Exhibit 1.
NOTE: Space heaters must energized for the minimum amount of time required by the
manufacturer prior to attempting a motor start. If no guidelines are given the heater should
be energized for 8 hours prior to attempting the start.

6.4

6.3.7

After the preliminary rotation verification all motors must be bumped for a final
verification of proper rotation.

6.3.8

Ensure that the safety switch adjacent to the motor is function checked before starting
motor.
Motor solo run shall be done all MV motor and installed outdoor

LV motor.
But some motors are not dismantle mechanical coupling. Their
Motor Start and Run motors shall not be applied motor solo run test.
6.4.1

If, at any time during the implementation of this procedure, any parameter or condition is
out of acceptable limits and cannot be readily corrected, the evolution in progress shall be
terminated and the system or component placed in a safe configuration.

6.4.2

Clamp an ammeter on one of the motor leads at the breaker and set it to record the
maximum current draw. Alternatively if the motor manager or protection relay can record
starting current, this should be used instead of clamp on ammeter. Start the motor, locally
if possible. Record the starting current on the Motor Data Record, Exhibit 1.

6.4.3

As the motor comes up to speed, monitor it for smoothness of operation and for any
unusual or unexpected noises.

6.4.4

with the motor running: take running current on all phases, phase to phase voltages, and
motor rpm measurements and verify that the motor space heater is de-energized. Record
readings on the Motor Data Record, Exhibit 1.

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
Issue Date:

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RSAE-MTS-QA-EL-009

Revision:

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6.4.5

If applicable tune variable speed drive to the system attributes and verify frequency
settings.

6.4.6

Check that the motor bearings are being properly lubricated (e.g. bearing oil rings are
rotating, no excessive foaming, levels are correct). Monitor bearing temperatures as the
motor is run in. When they have stabilized, record the measurement.

6.4.7

Monitor motor winding temperatures, if available. When they have stabilized, record
measurements on the Motor Data Record, Exhibit 1, in the comment section.

6.4.8

Take vibration data as required. Refer to Equipment Vibration Testing Procedure.

Vibration readings that exceed limits may result in motor damage, and operation may have
to be secured.

6.4.9

Verify temperature, current, and vibration readings against any local or remote indications.

6.4.10 Verify magnetic centre position indication, if applicable. Apply new mark if necessary.
6.4.11 When the vendors run-in criteria have been met or the temperatures are stable secure the
motor and monitor for smooth coast down.
after vendor's confirmation
6.4.12 Repeat the activities of the uncoupled motor start and run-in when the motor is coupled.
Record the data on the Motor Data Record, Exhibit 1.
6.4.13 After final alignment and motor and driven equipment run-in, the motor may be doweled in
position as required by the vendor.
6.4.14 Ensure that motor stops when safety switch is put in off position and cannot be started
again from PCS.
local control stop button

To be submitted in case
restoration is required

6.5

Restoration

6.5.1

Verify that temporary alterations made during the performance of this test have been
restored or controlled according to Control of Temporary Modifications Procedure.

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 Thule Data Records have been completed.

previous data records

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
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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. Exhibits
1Motor Data Record
9. Attachments
AMotor Run Testing Process Map

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS

Issue Date:

Test format to be same format as ITP

Doc. Number: RSAE-MTS-QA-EL-009
Revision:

19/09/2014

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EXHIBIT 1
Motor DATA RECORD
SDN No.______-___-___-____-_____-___ SHEET_1_ OF ___
EQUIPMENT IDENTIFICATION
FACILITY/PROJECT

UNIT NO.

JOB NO.

SYSTEM NAME/NUMBER

EQUIPMENT NAME/NUMBER

POWER SOURCE

DRAWINGS
TEST ENGINEER
DATE
__________________________/______
__

PREREQUISTIES COMPLETE AND SAFETY PRECAUTIONS

READ AND COMPLIED WITH:
MOTOR NAMEPLATE DATA
MFG

ID#

SERV #

VOLTS

AMPS

AMPS

RPM

FRAME

HZ

HP/KW

ENCL

CODE

DUTY

AMB

SF

TYPE

INSUL.
CLASS
IB/DE

NEMA
DESIGN.

NEMA EFF.

# BRG'S

OB/NDE
MOTOR OPERATING DATA

MEGGER READINGS
WINDING
RESISTANCE
APPLIED
VOLTAGES

A-G

MOHMS

A-B

B-C

OHMS
A-B
VOLTS

B-C
VOLTS

PHASE SEQUENCE
STARTING CURRENT (AMPS)
MODE

OHMS

MOHMS
C-A

C-A
VOLTS

OHMS
P-N

VOLTS

BUS VOLTAGE
VOLTS
RPM
RUNNING CURRENT (AMPS)
UNCOUPLE
D

COUPLED,
LOW
ROTATION:
CW
COUPLED,
MEDIUM
CCW
COUPLED,
HIGH
ELEC.COMM.ENGINEER (PRINT/SIGN)

PHASE
A

UNCOUPL
ED

N-G

COUPLED

EMPLOYER ENGINEER (PRINT/SIGN)

DATE
DATE

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
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EXHIBIT 1
Motor DATA RECORD (CONTD.)
()
SHEET_2_ OF ___
MOTOR OPERATING DATA (CONTD)
Time
Param.

(0)
:

(0:10)
:

(0:20)
:

(0:30)
:

(0:40)
:

(0:50)
:

(1:00)
:

(1:10)
:

(1:20)
:

(1:30)
:

DE
Brg.
Temp.
NDE
Brg.
Temp.

MEASURING AND TEST EQUIPMENT

TEST INSTRUMENT

MANUF./MODEL

M&TE/TAG NUMBER

CAL. DUE DATE

TEST MODIFICATIONS
MODIFICATION

INSTALLED
ELEC. COMM.ENG. /
DATE

RESTORED
ELE.COMM.ENG. /
DATE

COMMENTS
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________
ELEC. COMM. ENGINEER (PRINT/SIGN)

DATE

EMPLOYER ENGINEER (PRINT/SIGN)

DATE

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
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Revision:

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Page:

Attachment A
Motor Run Testing Process Map

Test Organization
Home Office

Test Program
Manager

Accept turnover
from Construction

Test Engineer

Construction

Inspect for correct installation,

lubrication, cleanness, correct
voltage, phasing, & frequency,
etc.

Include " Install

Lockout & Tagout on
breaker for power
supply" sentence

Verify motor
protection and
control circuits have
been checked out

Are motor MV motor

or LV motor installed
outdoor

Is motor
250V dc
or 480V ac of
more than 50HP/
37.5kW?

Yes

Uncouple
motor from
driven
equipment

If possible

No

Hand rotate shaft

and check for
rubbing

MHI comment:
Motor megger always
shall be done before
motor solorun

Has motor
been meggered
recently?

Yes

Measure winding
resistance and applied
voltage phase to phase

Please check phase

rotation for all motors as
your procedure.

Megger per 530U07-00308,

Insulation
Resistance
(Megger) Testing

No

Can motor
or driven equipment
be damaged by
reverse rotation?

No

To Page
2

Phase to Ground

Yes

Verify phase
rotation with
phase rotation
meter

Engineering

13 of 14

New Acrylic Acid Plant, Salavat, Bashkortostan Russia Federation

Method Statement for

MOTORS
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Revision:

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Page:

Attachment A
Motor Run Testing Process Map (contd.)

Test Organization
Home Office

Test Program
Manager

Include " Remove

Install Lockout & Tag
out on breaker of
power supply"
sentence

Test Engineer

Construction

From
Page 1

Place support
systems in service

Close breaker/rackin switchgear

Bump motor to check

for rotation

Is rotation
correct?

No

Swap leads to
correct rotation
and update
markings

Yes

Start and run motor,

taking data and
monitoring operation

Verify heater deenergizes if applicable

All motor of RSAE PJ is

greater than 120V ac rated
voltage.

Is motor
greater than
120V ac or
125V DC?
Yes

Run-in motor until

bearing and winding
temperatures are
stable and all other
vendor run-in criteria
are met

Secure motor and

monitor for smooth
coast down

END

No

Run-in motor for

5 minutes unless
vendor specifies
otherwise

Engineering

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