Best Practice

SABP-G-005 29 December 2004 Synchronous Motors Dynamic Analysis Factory Acceptance Test Document Responsibility: Consulting Services Department

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 Introduction.................................................... References.................................................... General.......................................................... Definitions...................................................... Vibration Detectors........................................ Tests Procedure............................................ FAT Acceptance Criteria................................ 2 2 3 3 4 4 5

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Next Planned Update: 1 January 2009 Page 1 of 7

Primary contact: Khaleel M. Al-Hussain on 873-0311

Document Responsibility: Consulting Services Dept. Issue Date: 29 December 2004 Next Planned Update: 1 January 2010

SABP-G-005 Synchronous Motors Dynamic Analysis Factory Acceptance Test

Introduction 1.1 Purpose The purpose of this Practice is to establish guidelines in reviewing the dynamic analysis of synchronous motors during Factory Acceptance Test (FAT). 1.2 Scope This Best Practice gives general guidelines for reviewing vibration instrumentation requirements, test procedure and acceptance limits during the Factory Acceptance Test and does not include performance test criteria. 1.3 Disclaimer This Best Practice is being provided for the general guidance and benefit of Saudi Aramco engineers attending synchronous motor Factory Acceptance Test (FAT). The use of this Best Practice during factory acceptance test, however, does not relieve the manufacturer from his responsibility or duty to confirm or to verify the accuracy of any information presented or from his contractual liability to perform an accurate FAT that conforms to Mandatory Saudi Aramco Engineering Requirements. The use of the information or material contained herein will not guarantee that the resulting product satisfies the applicable requirements of Saudi Aramco Standards. Saudi Aramco assumes no responsibility or liability whatsoever for any reliance on the information presented herein or for FAT performed by manufacturer in accordance with this Best Practice document. Moreover, this Best Practice is intended only to provide guidelines for Saudi Aramco engineers attending the Factory Acceptance Test and shall not be considered as a replacement for the Mandatory Saudi Aramco Engineering Requirements. Saudi Aramco is a registered trademark of the Saudi Arabian Oil Company. Copyright, Saudi Aramco, 2004. 1.4 Conflicts with Mandatory Standards In the event of a conflict between this Best Practice and other Mandatory Saudi Aramco Engineering Requirement, the Mandatory Saudi Aramco Engineering Requirement shall govern.

References This Best Practice is based on the below referenced standard: 2.1 Saudi Aramco References

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Document Responsibility: Consulting Services Dept. Issue Date: 29 December 2004 Next Planned Update: 1 January 2010

SABP-G-005 Synchronous Motors Dynamic Analysis Factory Acceptance Test

Saudi Aramco Engineering Standard SAES-P-113 Motors and Generators (31 July, 2004)

Saudi Aramco Materials System Specifications 17-SAMSS-520 34-SAMSS-625 2.2 Form-Wound Brushless Synchronous Motors (28 January, 2004) Machinery Protection Systems (30 June, 2002)

Industry Codes and Standards American Petroleum Institute (API) API STD 546 API STD 670 Brushless Synchronous Machines-500 KVA and Larger, 2nd Edition Machinery Protection Systems, 4th Edition

General This best practice gives general guidelines for the vibration instrumentation requirements, test procedure and acceptable limits during synchronous motors factory acceptance test. If rotordynamic analysis is required, according to 17-SAMSS-520/API STD 546, then it should be reviewed by the attendee prior to the test. The vendor shall notify the purchaser not less than ten working days before the date the equipment will be ready for testing (API STD 546/ P 4.3.1.2). However, it is suggested that the vendor send notification six weeks prior to any witness test. At least 6 weeks before the first scheduled test, the vendor shall submit to the purchaser, for review and comment, detailed procedures for all tests, including acceptance criteria for all monitored parameters (API STD 546/ P 4.3.1.4).

Definitions Factory Acceptance Test (FAT): It is a test conducted at a factory to ensure that the motor meets its required performance and mechanical integrity. Acceptance Level: This is the vibration level (displacement, velocity, or acceleration) at which a machine can run indefinitely without inducing vibration related maintenance. Cold start: A motor start that occurs when the rotor and stator are initially at ambient temperature (API STD 546/ P 1.5.7).

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Document Responsibility: Consulting Services Dept. Issue Date: 29 December 2004 Next Planned Update: 1 January 2010

SABP-G-005 Synchronous Motors Dynamic Analysis Factory Acceptance Test

Hot start: Any restart of the motor that occurs when the motor is at a temperature above ambient temperature (API STD 546/ P 1.5.8). Lateral critical speed: Corresponds to resonant frequencies of the rotor, bearings, and bearing support system (API STD 546/ P 1.5.9). Trip speed (in RPM): The speed at which the independent emergency speed device operates to shut down the machine (API STD 546/ P 1.5.13). 5 Vibration Detectors Vibration detection equipment shall be provided as per the below Table. Table-1: Required Vibration Instrumentation for Synchronous Motors
HP Rating > 250 HP Motor with Antifriction Bearings 250 -500 HP Horizontal (Hydrodynamic Radial Brg.) 500 -1000 HP Horizontal (Hydrodynamic Radial Brg.) > 1000 HP Horizontal (Hydrodynamic Radial Brg.) > 250 HP Vertical Motor * Special Purpose Motor with Hydrodynamic Radial & Thrust Brgs.

Relative Measurement
Radial Thrust Key

Seismic Measurement Reading at the monitor

Velocity One /radial Brg. One /radial Brg. Acceleration

Provisions for X&Y X&Y

Provision Yes

One /radial Brg.

Two on the top radial Brg. X&Y Dual Yes

* Special Purpose Motors are the motors that drive high-inertia loads, vertical machines that support high thrust loads, part of a complete train requiring vibration sensitivity criteria, operate in abnormally hostile environments, or are critical unspared equipment (API STD 546 paragraph 1.1.1 Note 2).

Vibration detectors shall be provided, installed and calibrated in accordance with 34-SAMSS-625. 6 Tests Procedure 6.1 For motors 2000 kW (2682 HP) and above which operate at or above 3600 RPM, the vendor shall provide a damped unbalanced response analysis for each speed from zero to 115% of the maximum operating speed (17-SAMSS-520/ P 2.4.6.2.2).
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Document Responsibility: Consulting Services Dept. Issue Date: 29 December 2004 Next Planned Update: 1 January 2010

SABP-G-005 Synchronous Motors Dynamic Analysis Factory Acceptance Test

6.2 6.3

Bearing housing overall velocity should be measured in in/sec (mm/sec) RMS and shaft vibration in mils (m) pk-pk. The combined total electrical and mechanical runout for radial position probes shall not exceed 0.35 mils (9 m) for machines operating at 1800 RPM or less, or 0.25 mils (6 m) for machines operating above 1800 RPM. If the combined runout exceeds these values, reasonable attempts shall be made to reduce the runout. After all reasonable attempts are made to reduce the runout, 0.5 mils (13 m) will constitute an acceptable combined runout level. Records of runout tests before and after attempts to correct excessive runout shall be available for inspection on request (17-SAMSS-520/ P 2.4.5.1.3). The combined total electrical and mechanical runout for axial position probes shall not exceed 0.5 mils (13 m) (API STD 546/ P 2.4.5.1.3). vibration shall be measured to determine the mechanical performance and acceptability of all machines. This test is to be performed during the bearing temperature rise test and, hot run test.

6.4 6.5

FAT Acceptance Criteria 7.1 Before mounting the coupling, the machine shall be properly mounted on a massive foundation and run until the bearing temperatures stabilize. The voltage shall be reduced to of rated to minimize electrically induced vibration and lX filtered vibration data taken without the coupling mounted and again after mounting the coupling. The magnitude of the vectorial change in the lX vibration on the shaft and bearing housings shall not exceed 10% of the vibration limits given in Figures 1 and 2 (API STD 546/ P 4.3.1.5.2). During the test with rated voltage, the rotor shall be maintained on magnetic center. With the coupling mounted, the voltage shall be increased to rated and a complete set of filtered and unfiltered vibration data shall be taken. All data shall be within the limits given in Figures 1 and 2. If the vibration change or amplitude exceeds the allowable limits, the vendor and purchaser shall mutually agree on the appropriate corrective action (API STD 546/ P 4.3.1.5.2). Motors purchased with the driven equipment and generators purchased with drivers shall additionally meet the following requirements, when coupled to the driven equipment and operated at rated voltage and speed. The maximum shaft relative motion shall not exceed (17-SAMSS-520/ P 2.4.6.4): i 25.4 x (8,000/N)0.5 micrometers [(8,000/N)0.5 mils] or 38 micrometers (1.5 mils), whichever is less where N is the synchronous speed in RPM. If the final probe track runout exceeds 6 micrometers (0.25 mils), then the

7.2

7.3

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Document Responsibility: Consulting Services Dept. Issue Date: 29 December 2004 Next Planned Update: 1 January 2010

SABP-G-005 Synchronous Motors Dynamic Analysis Factory Acceptance Test

vibration readings shall be phase compensated for the measured final runout in order to determine the true vibration readings. ii The maximum bearing housing velocity, in any direction, shall not exceed 3 mm/s (0.12 in/sec) RMS.

Figure-1 (API STD 546): Shaft Vibration Limits (Relative to Bearing Housing Using Noncontact Vibration Probes): For all Hydrodynamic Sleeve Bearing Machines; With the Machine Securely Fastened to a Massive Foundation.
Notes: 1. The unfiltered vibration limits for machines up to 3,600 rpm rated speed shall not exceed 2 mils p-p displacement. For machines with rated speeds in excess of 3,600 rpm, the unfiltered vibration limit shall not exceed 12000 / N where N is the maximum rated continuous speed. 2. Vibration displacement at any filtered frequency below running-speed frequency shall not exceed 0.1 mil or 20% of the measured unfiltered vibration displacement, whichever is greater. 3. Vibration displacement at any filtered frequency above running-speed frequency shall not exceed 0.5 mil peak-to-peak. Page 6 of 7

Document Responsibility: Consulting Services Dept. Issue Date: 29 December 2004 Next Planned Update: 1 January 2010

SABP-G-005 Synchronous Motors Dynamic Analysis Factory Acceptance Test

4. Vibration displacement filtered at running speed frequency shall not exceed 80% of the unfiltered limit (runout compensated).

Figure-2 (API STD 546): Bearing Housing Radial and Axial Vibration Limits: For Sleeve and Antifriction Bearing Machines; With the Machine Securely Fastened to a Massive Foundation.
Notes: 1. The filtered and unfiltered vibration limits for machines up to 1,000 rpm rated speed shall not exceed 1.6 mils p-p displacement, and 0.1 inches per second true peak velocity for machines with rated speeds above 1,000 rpm. 2. For unfiltered vibration limits, use the machine synchronous or maximum rotational speed in rpm. 3. For filtered limits, use vibration frequency in hertz. 4. Limits are for sleeve and anti-friction bearing machines.

29 December, 2004

Revision Summary New Saudi Aramco Best Practice.

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