26 29 02.00 10.pdf

UFGS

SECTION 26 29 02 Page 1

SECTION 26 29 02.00 10

ELECTRIC MOTORS, 3-PHASE VERTICAL SYNCHRONOUS TYPE

04/06

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM A 123/A 123M (2002) Standard Specification for Zinc (Hot-

Dip Galvanized) Coatings on Iron and Steel

Products

ASTM A 153/A 153M (2005) Standard Specification for Zinc

Coating (Hot-Dip) on Iron and Steel Hardware

ASTM B 344 (2001) Standard Specification for Drawn or

Rolled Nickel-Chromium and Nickel-Chromium-

Iron Alloys for Electrical Heating Elements

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C37.96 (2000; R 2006) AC Motor Protection

IEEE C57.13 (1993; R 2003) Standard Requirements for

Instrument Transformers

IEEE Std 115 (1995; R 2002) Test Procedures for

Synchronous Machines: Part I: Acceptance and

Performance Testing; Part II: Test Procedures and Parameter Determination for Dynamic

Analysis

IEEE Std 43 (2000; R 2006) Testing Insulation Resistance of Rotating Machinery

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 4 (2005) Industrial Control and Systems:

Terminal Blocks

NEMA MG 1 (2007) Standard for Motors and Generators

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that

SECTION 26 29 02 Page 2 will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-02 Shop Drawings

Motors

Six copies of equipment foundation dimensions; outline drawings for motor and rotor set-down fixture and jacking provisions with weights, nameplate data, and details showing method of mounting and anchoring the motor. Contracting Officer's approval shall be obtained in writing prior to the commencement of manufacture of motors.

SD-03 Product Data

Insulated Windings

A detailed description of and specification for the manufacturing process, the materials and the insulating compound used in insulating the windings shall be submitted to the Contracting

Officer for approval before manufacture of the motors is commenced.

If, in the opinion of the Contracting Officer, the insulation proposed is not of the quality specified and if the methods of manufacture are not considered to be in accordance with best modern practice, the motors will not be accepted.

Witness Test

Six copies of motor design (characteristic) curves or tabulated data indicating the efficiency, current, and kilowatt input at rated voltage and 110 and 90 percent rated voltage all plotted or tabulated against torque or percent load as abscissas. Where values are given in percentages all base values will be indicated.

Six copies of the motor torque curves shall be plotted for the following values of voltage at the motor terminals: rated and 90 percent of rated voltage.

Motors

Six copies of complete descriptive specification for each type and size motor furnished, with necessary cuts, photographs, and drawings to clearly indicate the construction of the motor, specifications for the materials and treatments used to prevent corrosion of parts, and of bearing construction. A complete listing of motor performance data in the form provided in NEMA MG 1 paragraph 21.50 shall be submitted. Submittal shall include all information required for the selection of protective and control equipment and for operational settings. Information such as, but not limited to, normal and maximum operating temperatures for windings and bearings, V-curves, field control and protective equipment to be mounted on the motor controller cubicle, locked-rotor current, permissible locked-rotor time, starting times for each type of start as indicated above, and subtransient, transient, and synchronous reactance. If duplicate equipment has not been manufactured previously, calculations or tests shall be made as

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SECTION 26 29 02 Page 3 necessary and confirmed as required by paragraph FACTORY TESTS.

Contracting Officer's approval shall be obtained in writing prior to the commencement of manufacture of motors.

Spare Parts

The Contractor shall submit a complete list of renewal parts for the motor. The list shall accompany the instruction manuals.

Antireverse Device

The design of the antireverse device shall be submitted for approval of the Contracting Officer.

SD-06 Test Reports

Factory Tests

Six copies of test reports recording all data, calculations, and curves shall be furnished to the Contracting Officer for each motor used.

SD-07 Certificates

Power Factor and Efficiency

Six copies of certification guaranteeing value of power factor and efficiency for full load, 3/4 full load, and 1/2 full load.

Factory Tests

Complete Test

Check Tests

Six certified copies of the results of a "Complete Test" for duplicate equipment of the respective rating and type will be accepted in lieu of the "Complete Test" specified for equipment of the respective rating and type. No substitute will be accepted for the "Check Test".

SD-10 Operation and Maintenance Data

Manufacturer's Data and Instructions

Six copies of printed and bound instructions manual for the proper installation, erection, inspection, and maintenance of the machines furnished under this contract shall be supplied to the Contracting

Officer not later than the date the equipment is shipped from the manufacturer's plant. Manuals shall include complete installation, maintenance, and service instructions for the motors, lube oil system, thrust bearings (including cooling water requirements), and other accessories. The instructions shall include a cross-sectional drawing indicating the major component parts of the motor and procedure for disassembly. The description in the manual for the motor shall be coordinated with the installation erection instructions specified in Section 22 10 00.00 10 VERTICAL PUMPS, AXIAL-FLOW AND MIXED-FLOW IMPELLER-TYPE for the pump and integrated with same for a complete motor and pump assembly.

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SECTION 26 29 02 Page 4

1.3 GENERAL REQUIREMENTS

1.3.1 Corrosion Prevention and Finish Painting

The equipment provided under these specifications will be subjected to severe moisture conditions and shall be designed to render it resistant to corrosion from such exposure. The general requirements to be followed to mitigate corrosion are specified below. Any additional special treatment or requirement considered necessary for any individual items is specified under the respective item. However, other corrosion-resisting treatments that are the equivalent of those specified herein may, with the approval of the

Contracting Officer, be used.

1.3.1.1 Fastenings and Fittings

Where practicable, all screws, bolts, nuts, pins, studs, springs, washers, and other similar fittings shall be of corrosion-resisting material or shall be treated in an approved manner to render them resistant to corrosion.

1.3.1.2 Corrosion-Resisting Materials

Corrosion-resisting steel, copper, brass, bronze, copper-nickel, and nickel-copper alloys are acceptable corrosion-resisting materials.

1.3.1.3 Corrosion-Resisting Treatments

Hot-dip galvanizing shall be in accordance with ASTM A 123/A 123M or ASTM A

153/A 153M as applicable. Other corrosion-resisting treatments may be used if approved by the Contracting Officer.

1.3.1.4 Frames

Motor frames, end bells, covers, conduit boxes, and any other parts, if of steel, and if they will be coated during the process of insulating the windings, shall be cleaned of rust, grease, millscale, and dirt, and then treated and rinsed per manufacturers' standard process. If any of the above-listed parts are not coated during the process of insulating the windings then, in addition to the above, they shall be given two coats of primer and then two coats of manufacturers' standard moisture-resistant coating, processed as required.

1.3.1.5 Cores

The assembled motor core shall be thoroughly cleaned and then immediately primed by applying a minimum of two coats of a moisture-resisting and oil-resisting insulating compound. Air gap surfaces shall be given a minimum of one coat.

1.3.1.6 Shafts

Exposed surfaces of motor shafts shall be cleaned of rust, grease, and dirt and, except for bearing surfaces, given one coat of a zinc molybdate or equivalent primer and two coats of a moisture-proof coating, each cured as required. Shafts of a corrosion-resisting steel may be used in lieu of the above-mentioned treatment.

SECTION 26 29 02 Page 5

1.3.1.7 Finish Painting

Finish painting of all equipment shall be in accordance with the standard practice or recommendation of the manufacturer, as approved by the

Contracting Officer.

1.3.2 Winding Insulation

Insulation for the stator, rotor field, and exciter windings shall be full class "F" insulation as defined in NEMA MG 1 paragraph 1.66 and as described herein. The insulation system shall be a combination of materials and processes which provides high resistance to moisture, fungus, and other contaminants as experienced by a motor in the service conditions specified herein. The insulation system shall also be of a type designed and constructed to withstand severe humidity conditions and to function properly after long periods of idleness without first drying out. All windings and connections shall be of the sealed type as defined in NEMA MG 1 paragraph

1.27.2. Insulated windings, unless otherwise approved, shall be completely assembled in the motor core before impregnating with the insulating compound. The compound shall consist of 100 percent solid resin.

Impregnation of the windings with the insulating compound shall be by vacuum impregnation method followed by baking. The procedure shall be repeated as often as necessary to fill in and seal over the interstices of the winding, but in no case shall the number of dips and bakes be less than two dips and bakes when the vacuum method of impregnation is used. Insulation to ground shall be processed on the coil. Slot tubes or cells are not acceptable.

The insulation shall be of adequate thickness and breakdown strength throughout the length of the coil. Mica shall be used in the slot portion and shall be of adequate thickness to withstand the dielectric tests specified in paragraph FACTORY TESTS.

1.3.3 Nameplates

Nameplate data shall include rated voltage, rated full-load amperes, rated horsepower, service factor, number of phases, RPM at rated load, frequency, code letter, locked-rotor amperes, duty rating, insulation system designation, and maximum ambient design temperature.

1.3.4 Government Study

The Contractor shall supply to the Government, for completion of its Motor

Torque and Accelerating Time Studies (MTATS), the following data:

a. Complete equivalent circuit data referred to the stator with friction, windage, and stray load losses.

b. Current, power factor, and torque versus speed (0-100 percent, inclusive, in 1 percent increments up to 95 percent and

0.1 percent increments above 95 percent) and load (0-125 percent, inclusive, in 25 percent increments) as a function of line voltage

(from 80 percent to 110 percent, inclusive, in 5 percent increments), for rated and 90 percent of rated voltage at starter.

Only tabulated data will be required.

c. Load inertia, Wk2 of motor rotating parts, pound-foot2.

SECTION 26 29 02 Page 6

1.4 SYSTEM DESCRIPTION

The work under this section includes furnishing all labor, equipment, and material and performing all operations required to design, manufacture, assemble, factory test, prepare for shipment and storage, and to deliver the vertical synchronous motors required to drive the flood-control pumps specified under Section 22 10 00.00 10 VERTICAL PUMPS, AXIAL-FLOW AND MIXED-

FLOW IMPELLER-TYPE. These motors shall be supplied complete with all accessories, spare parts, tools, and manufacturer's data and instructions as specified herein.

1.5 DELIVERY, STORAGE, AND HANDLING

Each motor shall be shipped in the vertical position with the rotor blocked inside the stator to prevent damage to the bearings. The motor shall be securely mounted on a skid or pallet of ample size. All small parts or elements shall be boxed. The skid mounting and boxing shall be done in a manner which will prevent damage or distortion to the motor during loading, shipment, unloading, indoor storage, and subsequent handling. Weatherproof covers shall be provided as necessary to protect the motor during shipment.

Any eyebolts, special slings, strongbacks, or other devices used in loading the equipment at the manufacturer's plant shall be furnished for unloading and handling at the destination and shall become the property of the

Government.

1.5.1 Impact Recorder

Each motor shall be shipped with a three-way temporary impact recorder to measure magnitude and direction of longitudinal (Y), lateral (X), and vertical (Z) impacts suffered during shipment. If the recorder indicates impacts equal to or greater than those determined by the Contractor prior to shipment for any of the three directions specified herein, Contractor shall inspect and test motor to determine extent of damage, if any, and shall repair or replace any damaged equipment.

1.5.2 Long Term Storage

The Contractor shall, at no cost to the Government, store all equipment provided under this contract for 3 months. The storage site shall be subject to the approval of the Contracting Officer and shall meet the manufacturer's recommendations for indoor storage. The equipment will be subject to periodic inspection by the Government to ensure that proper storage conditions are maintained.

PART 2 PRODUCTS

2.1 MOTORS

The motors to be supplied under these specifications shall be of the vertical solid shaft type as required by the pump manufacturer, with direct-connected brushless exciter, designed for full voltage starting, of drip-proof construction, complete with antireversing ratchet or backstop device, and shall conform to the applicable requirements of NEMA MG 1, except as hereinafter specified.

2.1.1 Rating

SECTION 26 29 02 Page 7

Each motor shall be wound for three-phase, 60 Hz, alternating current, and for the respective operating voltage.

The motor shall be designed for operation in a 104 degrees F ambient temperature, and all temperature risers shall be above this ambient temperature. The rated horsepower of the motor shall be not less than 110 percent of the determined maximum load requirement of the pump. Motors shall have a power factor and service factor of 1.0. The temperature rise above the ambient temperature for continuous rated full load conditions and for the class of insulation specified shall not exceed the values given in

NEMA MG 1paragraph 21.40.

2.1.2 Operating Characteristics

2.1.2.1 Torques

Starting and accelerating torque shall be sufficient to start the pump and accelerate it against all torques experienced in passing to the pull-in speed under maximum head conditions and with rated excitation current and a terminal voltage equal to 90 percent of rated value. The pull-in torque shall exceed that required by the pump under maximum head conditions but shall not be less than 100 percent of motor full-load torque, with a terminal voltage equal to 90 percent of rated value. Pull-out torque shall not be less than 150 percent of motor full-load torque for one minute minimum and with a terminal voltage equal to 90 percent of rated value.

2.1.2.2 Locked-Rotor Current

The locked-rotor current shall not exceed 600 percent of rated nameplate full load running current.

2.1.2.3 Starting Capability

Each motor, when operating at rated voltage and frequency and on the basis of the connected pump load inertia, Wk2, and the speed-torque characteristics of the maximum load during starting conditions as furnished by the pump manufacturer, shall be capable of making the starts required in

NEMA MG 1 paragraph 21.43. A starting information nameplate setting forth the starting capabilities shall be provided on each motor in accordance with

NEMA MG 1 paragraph 21.43.3. This nameplate shall also include the minimum time at standstill and the minimum running time prior to an additional start.

2.1.2.4 Balance

The balance for each motor when measured in accordance with NEMA MG

1paragraph 20.53 shall not exceed the values specified in NEMA MG 1 paragraph 21.54. Each motor's characteristics shall be such that the maximum vibration requirements of Section 22 10 00.00 10 VERTICAL PUMPS, AXIAL-FLOW AND MIXED-FLOW IMPELLER-TYPE are met.

2.1.2.5 Noise

All motors shall operate at a noise level less than 85 decibels A-weighted mean sound pressure level (dBA). Noise shall be determined in accordance with NEMA MG 1 paragraph 21.53.

SECTION 26 29 02 Page 8

2.1.2.6 Overspeed Option

Each motor shall be designed to withstand indefinitely, without injury, the maximum overspeed to which the motor will be subjected when the pump to which it is connected is acting as hydraulic turbine under the maximum head with the pump discharge pipe open.

2.1.2.7 Antireverse Device

A self-actuated backstop device or antireversing ratchet, to prevent reverse rotation of the pump due to loss of power or failure of the electric prime mover, shall be installed as an integral part of the motor. The design of the device shall be submitted for approval of the Contracting Officer and be such that its action is without intentional delay or excessive backlash. It shall have sufficient capacity to prevent reverse rotation with a back flow through the pump due to a foot differential head. The device shall be precision machined and be complete with support housing and oil collector as required. An oil reservoir, independent of the one used for the thrust bearing, complete with oil-level gauge and 120-volt ac rated high and low level contacts shall be provided for the backstop device. The lubricant for the antireverse device shall contain a corrosion inhibitor, whose type and grade shall be shown on a special nameplate attached to the frame of the motor adjacent to the lubricating filling device.

2.1.2.8 Power Factor and Efficiency

The power factor and efficiency at full load, 3/4 full load, and 1/2 full load shall be not less than 0.9, 0.9, 0.9 and 0.9, 0.9, 0.9, respectively.

Motors will be rejected if factory tests specified in paragraph FACTORY

TESTS do not demonstrate that these values will be met or exceeded.

2.1.3 Frames and Brackets

Frames and end brackets shall be of cast iron, cast steel, or welded steel.

The mounting ring, unless otherwise approved, shall be built integral with the frame or lower end bracket. Contractor shall coordinate the motor installation with the mounting arrangement specified in Section 22 10 00.00

10 VERTICAL PUMPS: AXIAL-FLOW AND MIXED-FLOW IMPELLER-TYPE, paragraph BASE

PLATE AND SUPPORTS. All equipment and materials required to mount the motor, such as a base or pedestal, sole plates, and bolts or dowels, shall be furnished by the Contractor. Sufficient bolts and dowels shall be installed to prevent any possible movement of the motor assembly when the motor is subjected to stresses resulting from the most severe short-circuit conditions. Treatment against corrosion shall be as specified in paragraph

GENERAL REQUIREMENTS.

2.1.3.1 Stator Frame

The stator frame shall be rigid and sufficiently strong to support the weight of the upper bearing bracket load, the weight of the stator core and windings, and to sustain the operating torques without perceptible distortion.

2.1.3.2 Supporting Brackets

The upper bracket supporting the thrust bearing and upper guide bearings shall have sufficient strength and rigidity to support the weight of the

SECTION 26 29 02 Page 9 entire rotating element of the motor, together with the pump impeller and shaft, and the unbalanced hydraulic thrust of the pump impeller. The lower bracket supporting the lower guide bearing shall preferably be so designed and constructed that the entire rotor can be lifted out as a unit without disturbing the bearing alignment. If it is not feasible to construct the rotor so that it can be lifted out as a unit, then the lower bracket shall be supported on separate base plates or structure and shall be designed so that it can be removed through the stator. The maximum deflection of the thrust bearing support system at any point shall not exceed the limits set by the pump manufacturer to maintain proper clearances for any operating condition.

2.1.3.3 Eyebolts

Eyebolts, lugs, or other approved means shall be provided for assembling, dismantling, and removing the motors from above, utilizing the overhead pumping station building crane. All lifting devices for use in conjunction with the building crane shall be furnished with the motor.

2.1.3.4 Platforms and Stairways

Each motor shall be furnished with a platform and stairway complete with railing. An easily removed section of railing shall be provided so that the rotor shaft does not have to be hoisted above the railing when the rotor is removed. The platform shall also provide maintenance access as required by the motor furnished.

2.1.4 Guards and Protective Enclosures

All moving, energized, or other parts where accidental contact might be hazardous to personnel shall be equipped with adequate guards, rails, or other suitable enclosures to prevent accidental contact. All lubrication fittings shall be piped to convenient locations where they can be serviced from regularly utilized access ways without removal of the guards or enclosures.

2.1.5 Insulation against Stray Currents

The motor shall be adequately insulated against stray currents which may be set up by the field of the motor and which might cause injury to the motor or pump bearings. This insulation shall be arranged to break the possible path of such currents in not less than two places in series.

2.1.6 Motor Cooling

The motor shall be provided with an open-type system of ventilation, taking cooling air from above the operating floor level and discharging the heated air into the operating room through upper openings in the stator frame. The circulation of air shall be induced by means of the fan action of the rotor.

No openings to the air space below the operating level are to be used in the motor design for ventilation or other uses that are not reasonably airtight.

2.1.7 Stator

2.1.7.1 Stator Core

SECTION 26 29 02 Page 10

The cores shall be built up of separately punched thin laminations of low-hysteresis loss, nonaging, annealed, electrical silicon steel; assembled under heavy pressure; and clamped in such a manner as to ensure that the assembled core is tight at the top of the teeth of the laminated core.

Laminations shall be properly insulated from each other. Only laminations free from burrs shall be used, and care shall be taken to remove all burrs or projecting laminations from the slots of the assembled cores. Cores shall be keyed, dovetailed, or otherwise secured to the shaft or frame in an approved manner. Treatment against corrosion shall be as specified in paragraph GENERAL REQUIREMENTS.

2.1.7.2 Stator Coils

The coils shall be thoroughly insulated and treated with a moisture and fungus-resisting compound in such a way that air will be excluded and the insulation will be protected from the absorption of moisture. Additional insulation shall be provided for those portions of each coil which are within the slots. The coils shall fit the slots accurately and they shall be form wound and interchangeable. The end turns shall be so designed and supported that they will not be distorted under the most severe short-circuit conditions to which the motor may be subjected.

2.1.7.3 Insulated Stator Windings

The stator windings shall be insulated as specified in paragraph GENERAL

REQUIREMENTS. Coils shall be of such uniformity that the stator windings of all similarly rated motors will be alike, in shape and size, and interchangeable. The stator winding and end turn connections shall be fully braced to withstand repeated full voltage starts. The bracing system shall essentially eliminate coil vibration under these high current conditions as well as during normal operation. A tieless bracing system will be acceptable. If a tied system is used it shall be such that no tie depends upon the integrity of any other tie within the system.

2.1.7.4 Temperature Detectors

Six standard copper resistance-type temperature detectors, with a resistance of 10 ohms at 75 degrees F, shall be provided in the stator in accordance with NEMA MG 1 paragraph 20.63. Detectors shall be wired in accordance with paragraph ACCESSORY WIRING AND BOXES.

2.1.7.5 Grounding

The stator frame shall have provisions for solidly grounding to the station ground system which will be furnished and installed by others.

2.1.8 Rotor

The rotor shall be built in accordance with the best modern practice and in such a manner as to secure adequate strength for the operating conditions described herein. The pole pieces shall be built up of thin steel laminations accurately aligned and securely riveted or bolted together. It is preferred that the field poles be secured to the rotor structure by means of dovetails, but an alternate method of construction will be acceptable, provided that evidence of its adequacy, satisfactory to the Contracting

Officer, is submitted with the bid.

SECTION 26 29 02 Page 11

2.1.8.1 Field Windings

The field windings shall be insulated as specified in paragraph GENERAL

REQUIREMENTS. The field coils shall be adequately insulated between turns and from the pole pieces and shall be thoroughly braced to withstand the stresses which could be imposed under maximum pump speed.

2.1.8.2 Starting Windings

The starting windings shall be designed for full-voltage starting, securely built into the field poles and designed to ensure conservative stresses when the unit is operating at maximum pump speed. The bars shall be silver soldered or brazed to heavy end segments to form a low-resistance joint of high mechanical strength. The starting windings shall be designed to permit any pole or group of poles to be removed.

2.1.9 Exciter

Each synchronous motor shall be provided with a direct connected exciter without brushes, commutators, or additional bearings. The exciter shall be capable of supplying continuously, and without overheating, the excitation for the motor to which it is connected when the latter is operating at rated power factor, voltage, frequency, and horsepower. The field-protective function and the field switching and application function shall be accomplished by semiconductor elements mounted on suitable heat sinks supported on the motor rotor and ventilated by rotation of the rotor. The exciter shall be either built into or so arranged that it is ventilated from the main motor enclosure. The enclosure of the exciter shall be of drip-proof construction comparable to that of the motor. The control system shall apply excitation to the motor field at the speed and phase angle required to obtain maximum pull-in torque. Exciter windings shall be insulated as specified in paragraph GENERAL REQUIREMENTS. The field coils shall be adequately insulated between turns and from the pole pieces and shall be thoroughly braced to withstand the stresses which could be imposed under maximum pump speed.

2.1.10 Shaft

The motor shaft shall be made of high grade steel, finished all over, and of ample size to drive the pump under maximum load conditions. The shaft shall be of the solid type and shall be connected to the pump shaft with a rigid adjustable coupling. The Contractor shall coordinate the connection with the pump shaft and shall furnish a motor shaft with all provisions, fittings, and devices required to conform to the shafting arrangement specified in Section 22 10 00.00 10 VERTICAL PUMPS, AXIAL-FLOW AND MIXED-

FLOW IMPELLER-TYPE, paragraph SHAFTS. See paragraph GENERAL REQUIREMENTS for treatment against corrosion.

2.1.11 Bearings

2.1.11.1 Thrust Bearings

Thrust bearings shall be spring type located above the rotor. A design in which each pivot shoe rests upon a support of metal which may take a permanent deformation in order to equalize the load on the bearing shoes, or in which individual shoe pivots are supported on spring plates or spring disks, is not considered to be of the self-equalizing type and will not be

SECTION 26 29 02 Page 12 acceptable. The stationary shoes shall be babbitt-lined. The thrust bearing shall have ample capacity to support the maximum pump hydraulic thrust load plus the static load while operating under maximum rated pump conditions. The thrust bearing shall be capable of withstanding without injury the pump being started normally without prior jacking of the rotor.

The thrust bearing shall have a removable runner and shall be arranged to permit adjustments, dismantling, and assembly of the runner and shoes without disturbing the stator or rotor, other than jacking the load from the bearing. A spacer plate between the thrust bearing runner plate and the thrust block will not be permitted.

2.1.11.2 Guide Bearings

Except as permitted below, the motor shall be provided with two guide bearings, one located above the rotor and the other below the rotor. The guide bearings shall be capable of withstanding all stresses incident to the normal operation of the unit and to the maximum runaway speed. Both guide bearings shall be self-cooled, of the oil-immersed, self-oiling type, and adequate provision shall be made for preventing oil or oil vapor from entering the motor cooling system. The guide bearings shall be of the split-sleeve type and shall be designed and constructed so that they can be dismantled without disturbing the thrust bearing or the motor rotor. If desired, the Contractor may combine the thrust bearing and the upper guide bearing into a combination integral guide and thrust bearing assembly in a common housing. In such a combination bearing, the vertical side of the thrust-bearing block, but not the runner plate, shall be used as the journal surface.

2.1.11.3 Lubrication

The lubricating oil used shall contain a corrosion inhibitor. Type and grade of lubricant used shall be shown on a special nameplate which shall be attached to the frame of the motor adjacent to the bearing filling device.

In addition to the quantity of lubricant required to initially fill the system, spare lubricant shall be furnished in sufficient quantity to purge and refill the system. Each lubrication system shall include oil reservoirs, oil-level sight gauge, oil piping, valves, and necessary appurtenances.

2.1.11.4 Housing

Bearing housing shall be of a design and method of assembly that will permit ready removal of the bearings, and prevent escape of lubricant and entrance of foreign matter. The bearings shall be protected by the lubricant when the motor is idle. Suitable means shall be provided to apply and drain the lubricant.

2.1.11.5 Cooling

Each thrust bearing shall be self-cooling whenever possible. When required by motor speed or load, an oil cooler with suitable coils of corrosion-resisting metal shall be provided in the oil reservoir and shall be of sufficient capacity to maintain the oil at the proper temperature with 30 percent glycol cooling water entering the coils at a temperature of 30 degrees C and with a minimum pressure of 40 pounds per square inch. The cooler shall be designed for safe operation at a maximum working pressure of

50 pounds per square inch and shall be subjected at the factory to a

SECTION 26 29 02 Page 13 hydrostatic test pressure of 75 pounds per square inch for a period of one hour without leakage. Cooling water will be supplied by a central system, furnished by others, consisting of a radiator, circulating water pump, and piping system terminating at the exterior of each motor. If required an auxiliary-motor-driven circulating oil pump, rated at 480 volts, three-phase, with electrical leads terminated in a special terminal box on the motor, and an oil pressure sensing device shall be included in the bearing oil cooler system. The cooler system shall be constructed so that the thrust bearing can be readily inspected or removed for repairs. A water flow indicator with adjustable alarm contacts shall be included in the water supply line. The oil reservoir shall have an oil-level gauge with high and low level normally open contacts rated 120 volts ac.

2.1.11.6 Temperature Detectors

A standard copper resistance-type temperature detector, with a resistance of

10 ohms at 75 degrees F, shall be provided for each bearing. Casings shall be made of copper. Detectors shall be wired in accordance with paragraph

ACCESSORY WIRING AND BOXES.

2.1.12 Nameplate

Each motor shall have a nameplate listing motor characteristics in accordance with NEMA MG 1 paragraph 21.61. A separate starting information nameplate shall be furnished as specified in paragraph OPERATING

CHARACTERISTICS.

2.2 INSTRUMENTS AND GAUGES

The following instruments and gauges shall be furnished.

2.2.1 Thermometers

Indicating thermometers, Six-inch vapor-tension digital, with adjustable ungrounded alarm contacts suitable for 120 volts ac shall be provided for

(a) the thrust bearing, (b) the thrust bearing oil reservoir, and (c) each guide bearing. The bulbs shall be located so as to indicate the temperatures of the hottest parts. The thermometers shall be mounted on a thermometer panel furnished by the Contractor and located on the motor housing at a location approved by the Contracting Officer. Adequate length of tubing shall be provided with each thermometer. The bulb and tubing shall be insulated where necessary to prevent bearing currents. The digital thermometers shall be square, semi-flush type with black cases and minimum one (1) inch high display.

2.2.2 Temperature Relay

A pneumatic bearing temperature relay having two sets of electrically independent contacts, located close to the babbitt of the thrust bearing and each guide bearing shall be provided. Each relay shall close its contacts when the bearing temperature reaches approximately 220 degrees F. The contacts shall have a current-carrying capacity of not less than 10 amperes, shall be ungrounded, and shall be suitable for 120 volts ac. The relays shall be mounted in an approved accessible location and the leads brought to a terminal block mounted on the stator frames in an approved location. The bulbs for the temperature relays shall be easily accessible and constructed

SECTION 26 29 02 Page 14 for removal and testing without disturbing the bearing or bearing housing.

The tubing shall be insulated where necessary to prevent bearing currents.

2.2.3 Oil-Level Gauge

An oil-level gauge for each oil reservoir, with scale of sufficient length to indicate the oil level at all room and operating temperatures, shall be provided. The gauges shall be located near the reservoirs in an approved, accessible location where they can be easily read. Each oil-level gauge shall have adjustable high and low oil-level ungrounded alarm contacts suitable for 120 volts ac.

2.3 PIPING

All piping systems within the motor for bearings, including valves and fittings, shall be designed and furnished by the Contractor. The Contractor shall bring these connections out to approve positions at the bottom of the stator frame. All piping shall be clean inside and where ending in open connections for other work, ends shall be capped for protection. Valves and other operating devices shall be easily accessible, and gauges and indicating devices shall be mounted on a control panel as approved by the

Contracting Officer. Piping and fittings shall be of copper or brass as required. Valves shall have bronze seats and stems and shall be suitable for the service intended. At all points where the piping system must be disconnected for dismantling operations, bolted flange connections or unions shall be provided. Arrangement of piping and location of valves and joints shall be such that there will be a minimum of disturbance to piping or interference with other service when the motor is dismantled or parts are removed for inspection or repairs.

2.4 WINDING SPACE HEATERS

Heaters shall be installed in the lower section of the frame or wrapped around the winding end turns. They shall be designed for operation on 120 volts, single-phase, 60-Hz, alternating current and of sufficient capacity or wattage that, when energized, they will hold the temperature of the motor windings approximately 10 degrees C above the ambient temperature. Heaters shall be de-energized when motor is operating.

2.4.1 Construction

The heaters, except for wrap-around type, shall be of the tubular type, constructed with a chrome-nickel heating element embedded in a refractory insulating material, and encased in an approved watertight metal sheath.

They shall be designed for continuous operation and have a maximum watt density of 20 watts per square inch. The rate of heat dissipation shall be uniform throughout the effective length of the heater. Cartridge-type heaters of equivalent construction, as approved by the Contracting Officer, will be acceptable. Heaters installed around the winding end turns shall consist of the required turns of heating cable wrapped around the end turns and secured in place before the winding is impregnated.

2.4.2 Element

Heating element shall conform to the requirements of ASTM B 344 for an 80 percent nickel and 20 percent chromium alloy.

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2.4.3 Sheath

Sheath shall be of a corrosion-resisting, nonoxidizing metal and shall have a wall thickness not less than 0.025 inch.

2.4.4 Insulation

Insulation shall be a granular mineral refractory material, highly resistant to heat, and shall have a minimum specific resistance of 1,000 megohms per inch cubed at 1,000 degrees F. Insulation for the heating cable shall be suitable for a conductor temperature of 356 degrees F.

2.4.5 Terminals

Terminals of the heater, including the leads, shall be watertight and shall be provided with leads suitable for making connections to a separate drip-proof terminal box located on the motor frame. The terminal box shall be readily accessible through the crating, so that winding heaters can be energized while motors are in storage.

2.5 MAIN LEADS AND TERMINAL BOX

2.5.1 Stator Terminals

Insulated terminal leads shall receive a treatment equal to that of the motor winding. Six leads shall be brought out of the stator frame and connections shall be made as required for the current transformers in paragraph ACCESSORY WIRING AND BOXES. Terminal lugs for connection to the motor shielded single-conductor supply wiring shall be provided.

2.5.2 Stator Terminal Box

Drip-proof cast iron or steel terminal boxes, treated in the same manner specified for frames to resist corrosion, shall be supplied for housing the stator lead connections, surge capacitors, surge arresters, and current transformers and shall have adequate space to facilitate the installation and maintenance of cables and equipment. Boxes shall have a hinged lockable cover providing unrestricted access, be mounted on the motor frame, and shall have an auxiliary floor supporting structure, when required, supplied by the motor manufacturer. Conduit entrance shall be from the bottom. The boxes shall be designed to permit removal of the motor supply leads when the motor is removed. A "HIGH VOLTAGE - 480 VOLTS" warning sign shall be provided on the cover of the box.

2.6 SURGE PROTECTION

2.6.1 Surge Capacitors

A three-pole capacitor unit, equipped with built-in discharge resistors and using a non-polychlorinated biphenyl (non-PCB) insulating medium, shall be furnished and installed in the main terminal box. Each pole shall be rated

0.5 microfarad and 4,160 volts line-to-line. Removable bus links shall be provided for motor testing. These links shall be treated to resist corrosion, shall be designed to maintain a positive contact, and shall have low contact resistance.

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2.6.2 Surge Arresters

Surge arresters of the station type with porcelain tops shall be furnished and installed in the main terminal box. The arresters shall be of the metal-oxide type rated 4,500 maximum continuous operating voltages line-to-ground. Removable bus links shall be provided for motor testing. These links shall be treated to resist corrosion, shall be designed to maintain a positive contact, and shall have low contact resistance.

2.6.3 Space Heater

If recommended by the surge protection manufacturer, a space heater of adequate capacity and rated 120 volts shall be furnished and installed in the terminal box. Space heater maximum watt density shall not exceed 20 watts per square inch.

2.7 CURRENT TRANSFORMERS

Current transformer shall meet the applicable requirements of IEEE C57.13 and IEEE C37.96. Secondary circuits shall be grounded at the motor, and all leads from each individual transformer shall be brought out to terminal blocks. They shall be of the dry or compound-insulated type and shall be provided with a suitable means of mounting and for grounding the frame.

Each current transformer secondary lead shall be connected to a terminal block of the short-circuiting type and shall be conveniently located to permit short-circuiting the secondary windings without requiring access to the primary bus compartments. The polarity of the current transformers shall be plainly marked. Each motor shall be provided with three indoor dry-type window transformers with single secondary and rated 50/5 amperes, 600 volts. Current transformers shall have minimum full-wave insulation level of 10 kV and, when installed, shall meet the requirements for a 60 kV basic impulse level (BIL). The transformers shall be mounted in the main terminal box and shall be arranged in the "flux-balancing" connection. Each motor shall be provided with three current transformers of rated 4,160 and

60 kV basic impulse level (BIL). The transformers shall be mounted in the main terminal box and shall be connected in the wye point of the winding for use with differential relays. All current transformers shall be suitable for continuous operation at the full-rated voltage and current at a frequency of 60 Hz. All current transformers shall be designed to withstand, without damage, the thermal and mechanical stresses resulting from short-circuit currents corresponding to ratings of the breakers in the circuits to which they are connected.

2.8 ACCESSORY WIRING AND BOXES

Except for current transformer leads and field control leads, all accessory wiring shall terminate in an accessory terminal box, unless otherwise approved by the Contracting Officer. Boxes shall be drip-proof and treated in the same manner specified for frames to resist corrosion. The accessory terminal box shall be furnished with a door hinged full length and shall be mounted on the motor in a location approved by the Contracting Officer.

Rigid galvanized steel conduit shall be used wherever practicable and shall be arranged to make removal unnecessary when the motor is dismantled. A wiring diagram within the enclosure shall be provided for all circuits and each conductor shall be identified with the designation shown on the diagram. All wiring shall terminate on terminal blocks as specified below.

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2.8.1 Wiring

Except as otherwise approved, all wiring shall be 125 degrees C rated flexible copper conductors, No. 14 AWG minimum, with 600-volt insulation.

The size and type of temperature detector leads may be in accordance with the manufacturer's standard practice and, where required, shall be suitable for contact with lubricating oil. Each detector shall be connected by three leads to terminal blocks, with one wire connected to a common point on the blocks. The common point for the stator detectors shall be separate from that for the bearing detectors.

2.8.2 Terminal Blocks

All terminal blocks shall be molded closed-back type as defined in NEMA ICS

4, rated not less than 600 volts and shall be provided with covers. The terminals shall be screw-clamp type or stud-and-nut type. White or other light-colored marking strips, fastened by screws to the molded sections at each block, shall be provided for circuit designation. Each connected terminal of each block shall have the circuit designation or wire number permanently marked on a strip. Reversible or spare marking strips shall be furnished with each block and at least 10 percent spare terminals shall be provided.

2.9 JACKING PROVISIONS

Suitable means shall be provided for hydraulic jacking of the rotor to permit inspection, adjustment, or removal of the thrust bearing. Provisions shall also be made for blocking the rotor in the fully raised position. The blocking device shall not require maintenance of hydraulic pressure on the jacks while the assembly is in the raised position.

2.10 SPECIAL TOOLS AND EQUIPMENT

The Contractor shall provide special tools, jigs, fixtures, lifting tackle, and instruments which may be necessary in assembly, erection, operation, maintenance, and repair of equipment. Special tools and equipment are those the design, purpose, and use of which are peculiar to equipment furnished and which are not available from normal wholesale or retail outlets. The motor manufacturer shall provide hydraulic jacking devices as required in order to pull the thrust bearing thrust collar from the upper end of the shaft and shall also furnish one complete set of lifting attachments such as detachable eyebolts or special slings for handling various parts with a hoist.

2.11 SET-DOWN FIXTURES

The Contractor shall furnish one separate motor set-down fixture for each motor rating supplied. This fixture, when installed on the operating floor, shall provide sufficient clearance above the floor for the motor shaft and coupling extending below the motor frame. The fixture shall be suitable for holding the motor during assembly and disassembly. The Contractor shall also furnish one separate rotor set-down fixture for each motor rating supplied. The fixture shall hold the rotor in the horizontal position above the floor without unduly stressing the rotor pole pieces or laminations.

The motor and rotor fixtures shall be shipped to the pumping station prior to the shipment of any motor.

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2.12 FACTORY TESTS

One motor of each rating and type selected at random by the Contracting

Officer shall be given a complete test. The remainder of the motors shall be given a check test. All complete tests shall be waived in writing.

2.12.1 Witness Test

When the Contractor is satisfied that a motor selected for a "Complete Test" performs in accordance with the requirements of the specifications, the

Contracting Officer shall be notified and shall be furnished with two copies of the tabulated data, calculations, and curves required by paragraph

COMPLETE TEST below or required to confirm the data required in paragraph

SUBMITTALS. Three weeks will be required, after receipt, to review the foregoing information. Should the witness test indicate that a motor does not perform in accordance with the requirements of the specifications, changes or corrections shall be made and new complete witness tests run, at no additional cost to the Government.

2.12.2 Complete Test

A complete test of a synchronous motor shall including the following:

a. Resistance of armature and field windings.

b. Polarity of field coils.

c. High-potential tests of armature and field windings in accordance with NEMA MG 1 paragraph 21.52.

d. Air gap measurement.

e. V-curves (for zero, 1/2, 3/4, and full load).

f. Determination of the subtransient, transient, and synchronous reactance.

g. Conventional efficiency tests, in accordance with NEMA MG 1paragraph

21.44. Motor shall meet manufacturer's published efficiency criteria for 1/2, 3/4, and full rated loads. Calculation of efficiency shall include bearing loss due to external thrust load.

h. Tests to determine temperature rise in accordance with NEMA MG 1 paragraph 21.40.

i. Insulation resistance-temperature test, in accordance with IEEE Std

43. Test result values shall be plotted on semilogarithmic graphs, the insulation resistance values as logarithmic ordinates and the temperature values as uniform abscissas. Readings shall be taken at approximately 10 degrees C intervals. Temperature shall be determined by the resistance method. Also, for comparison purposes, a curve indicating the safe operating value of insulation resistance shall be plotted on the same sheet.

j. Noise level tests in accordance with NEMA MG 1 paragraph 20-50.

k. Motor balance in accordance with NEMA MG 1 paragraph 20.54.

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l. Conformance test in accordance with NEMA MG 1 paragraph 20.49.

m. Torques. Torque tests shall be performed in accordance with IEEE

Std 115 to demonstrate that the values specified in paragraph

"Torques," will be met or exceeded.

2.12.3 Check Tests

A check test of a synchronous motor and exciter shall include the following:

a. Routine test per NEMA MG 1 paragraph 21.51.

b. Cold resistance measurement.

c. Insulation resistance and winding temperature at time the insulation resistance was measured.

d. Conformance test in accordance with NEMA MG 1 paragraph 20.49.

e. Motor balance in accordance with NEMA MG 1 paragraph 20.54.

2.12.4 Stator Winding Coil Tests

All coils, either before or after they are placed in the slots, shall be tested for short circuits between turns of the individual coils by applying a high frequency voltage of not less than 75 percent of the voltage for which the machine is insulated, or by applying a surge test voltage of equivalent value to the terminals of each coil. Equivalent surge voltage shall be a wave whose peak value is equal to 1.06 times the voltage for which the motor is insulated.

2.12.5 Space Heater Tests

Each winding space heater unit shall be tested at the factory for successful operation and dielectric strength.

2.13 RENEWAL PARTS

The following renewal parts shall be furnished for each type and rating in addition to the assembled motors:

a. Two complete stator coils but not…