SPECIFICATIONS OF MOTORS AND STARTERSFOR NAVAL SHIPS
EEDQ071 (R4)
May 14
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M A T E R I A L B R A N C HDIRECTORATE OF ELECTRICAL ENGINEERING
I N T E G R A T E D H E A D Q U A R T E R SM O D ( N A V Y )
‘D’ WING, SENA BHAWANN E W D E L H I 1 1 0 0 1 1
Record of Amendments
SL NO AMENDMENT AUTHORITY
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SIGNATURE
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Revision Note: Nil
Historical Record: Nil
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Contents
Section Subject Page No
I Scope 6II Related Documents 78III Definition 9
IVInformation and Drawings Supplied While Tendering 10
V Motors 1123VI Starters 2434VII Inspection & Testing 3542VIII Drawing & Documentation 4350IX Spares and Product Support 5152
Sl No Appendix Page No1. Appendix A `X’ Form
5354
2. Appendix B Commercial Motors 5556
3. Appendix C Shock Curve NSS GradeIAppendix ‘C’ 57
4. Appendix D Shock Curve NSS Grade –IIAppendix ‘D’ 58
5. Appendix E Standardised Range of Motors 59
6. Appendix F Power Supply Characteristic of Ships Main AC Supply 60
7.Appendix G Standardised Range of Starters and Motors for Various Services
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8. Appendix H Test Required On AC Motors and their Control Gears
6263
9. Appendix J Chart on Type 2 coordination for Starters.
6466
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Introduction
1. This EEDQ071 (R4) Electrical Specification applicable to all AC Motors and starters being fitted onboard Indian Naval Ships and Crafts and is sponsored by the Indian Navy, Naval Headquarters, Directorate of Electrical Engineering, Sena Bhavan, New Delhi 110 011
2. It is to be applied as required for contracts concerning supply of Motors and Starters for Indian Naval ships
3. If it is found to be technically unsuitable for any particular requirement, the Sponsor is to be informed in writing of the circumstances with a copy to Directorate of Electrical Engineering, Naval Headquarters, Sena Bhavan, New Delhi110011
4. Any user of this Specification may propose an amendment to it. Proposals for amendments which are:
(a) Not directly applicable to a particular contract are to be made to the Sponsor of the EEDQ071 (R4).
(b) Directly applicable to a particular contract are to be dealt with using existing procedures or as specified in the contract.
5. No alteration is to be made to this EEDQ specification except by the issue of a formal amendment by Director of Electrical Engineering, Naval Headquarters.
6. Unless otherwise stated, reference in this EEDQ specification, to “approval”, “approved”, “authorized” or similar terms means “by the Naval Headquarters”.
7. Applicability. This applicability of the revised EEDQ071 (R4) is as follows:
(a) All new procurements by Commands/Dockyards.
(b) All procurements by Shipyards for new construction ships where the build specs specifically indicates the revised EED.
(c) The revised EED will not be applicable to any existing orders or any repeat orders for ongoing / existing contracts which are being progressed as per the earlier EED EEDQ071 (R3).
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SECTION I
SCOPE
0101. This specification covers the Statement of Technical Requirements for A.C motors and their control gear (Starters) to be fitted on Indian Naval Warships and other Naval ships/crafts built in accordance with classification society’s rules and regulation. The A C Motors, Starters and associate control equipment shall be designed to meet the input supply characteristics and duty cycle. The design is to be catered for the most adverse of the environmental and electrical conditions. It also specifies the design, performance, various tests required and their procedures, documentation, supply of onboard and Base & Depot spares.
0102. Consideration to departure from the specification will be given when difficulties are encountered during the construction of machine. Any deviation from these specifications would be considered only with prior approval of NHQ/DEE.
0103. Statement of requirement is to be deemed to take precedence over this specification and any other documents quoted therein.
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SECTION II
RELATED DOCUMENTS AND APPLICABLE STANDARDS
0201. The following documentation or the latest issue in effect is to form a part of this specification to the extent specified herein, except where a specific issue is indicated. In case of a conflict between the contents of this document and the applicable portions of the referenced documents, the contents of this document shall take precedence.
0202. Reference to following documents is made in this EEDQ:
SL No Related Documents Clause(a) IS325/IS 12615:2011 Specification for three phase
induction motor5.4.2.5.3(B)
(b) IS919 Part 1 & Part 2 Recommendation for limits and fits for engineering
3.7.20
(c) IS1231 Dimensions of three phase foot mounted induction motors
44.1.1
(d) IS1897 Copper strip for electrical purposes 3.11.1(e) IS 2293:1974/IS 2048 Specifications for parallel key
and keyways 3.7.18
(f) IS2101 Recommendations for limits and fits for size above 500mm up to 3150mm
3.7.20
(g) IS2223 Dimensions of flanged mounted AC induction motors
4.1.1
(h) IS2254 Dimensions of vertical shaft motors for pumps 4.1.1(j) IAS2292 Specification for taper key and key ways 3.7.18(k) IS/IEC 600345 Degrees of protection provided by
enclosure for rotating electrical machinery5.4.4.1.2
(l) IS4825 Laboratory and reference thermometers 5.4.2.5.3(a)(m) IS 12615: 2011 Energy efficient three phase squirrel
cage induction motors 17.1
(n) IBS970 Wrought steels in the form of Blooms, Billets, 3.7.166
SL No Related Documents Clausebars and forging
(p) BS1399 Definitions, formulae and constants part 1 relating to the humidity of air
3.7.19
(q) BS1400 Copper alloy ingots and copper alloy castings
3.6.2
(r) IS/IEC 600790:2004, IS/IEC 600791:2007 Construction and testing of flame proof enclosure of electrical apparatus
3.2.1(b)
(s) BS 6121/EN 6244402013 For double compression cable glands of Brass as per BS6121, with IP 67/68 Protection.
(t) JSS55555 Environmental tests methods for Electronic and Electrical equipment
5.4.4.1.3 to 5.4.4.1.5
(u) NES632 Requirement of AC & DC Motors (v) NES636 Requirement of AC & DC starting control
gear (starter)
(w) IS2147 For enclosures of Motors and Starters. (x) NES501 General requirement for the design of
electro technical equipment
(y) BS 5424 Control Gear voltages upto and including 1000 VAC part 1 – Contactors.
(z) NES 0723 Tally/diagram plate
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SECTION III
DEFINITIONS
0300. Vendor/Firm/OEM. The agency responsible for undertaking the actual design task and for producing the Configuration Definition of the equipment. For the purposes of this EEDQ the Design Authority will normally be a Contractor entrusted with a Development Contract supported by a Statement of Technical Requirements (SOTR). The Design Authority may subcontract some of the detailed design or drawing work, but nevertheless retains the ultimate technical design responsibility. The Design Authority ‘Certifies’ the manufacturing drawings, and in so doing accepts responsibility for the technical correctness of the design.
0301. Main Contractor: The manufacturer legally contracted by Indian Navy and/or the delegated design agent to supply the overall functioning unit.
0302. Statement of Technical Requirements (SOTR): The description of a job or package of work for the full development or limited development of a ship, system or equipment. A form of specification that must convey the intent of one party to another in such a way that there is never any doubt on the meaning of each and every individual requirement. A number of SOTR’s may be required in order to state the requirement for the stages within the total development task the final outcome of which will be a Configuration Definition.
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SECTION IV
INFORMATION AND DRAWINGS TO BE SUPPLIED WHILE TENDERING
0401. The preparation and submission of Approval and As Made drawings/information, when called for in the contract or order, is to be in accordance with NES 505, NES 628 and NES 722.
0402. For Tender drawings/information see NES 628.
0403. When tendering for electric motors the Design Authority/Main Contractor is to raise an ‘X’ Form or specification based on the ‘X’ Form detailing Mandatory Design Requirements (see Appendix ‘A’ ).
0404. When called for, tender drawings of the starters are to comprise three clear prints of the outline of the equipment, showing approximate overall dimensions, estimated weight and position and size of mounting arrangements. For tender purposes these drawings may be submitted in the Contractor’s own style and format.
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SECTION V
MOTORS5. General
0501. Motors are the workhorses of electrical systems on board ships and therefore must be constructed in accordance with the specifications and in strict compliance to the approved drawings. Deviations, if any, from these specifications shall be accorded by NHQ/DEE.
0502. Any approved alteration or addition of a minor nature found necessary during the construction of the motor is to be carried out by the manufacturer without extra charges. The manufacturer is to keep in mind continuously the fact that, economy of weight and space is of utmost importance.
0503. Wherever items are described in specification and are not indicated in the drawings OR are indicated in drawings but not described in specifications; such items are deemed to be the requirement of both specifications and drawings.
0504. The manufacturer shall ensure attaining specified quality, workmanship endurance, and electrical characteristics of the motor.
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0505. All components, fittings, fixtures etc. shall be of reputed make and their installation work shall be in accordance with the standard marine practice and shall satisfy NHQ/Inspecting Agency.
0506. All parts, subassemblies and components shall comply with the requirement of drawings and specification to the satisfaction of the NHQ/Inspecting Agency.
0507. No materials, parts, components or complete units, which have been rejected, shall be retreated or adjusted without the approval of the NHQ/Inspecting Agency.
Technical Specifications
0508. The motors shall be capable of developing specified rated output at specified environmental conditions, ambient temperature, voltage and frequency. While developing the rated output at such extreme conditions, the temperature rise of the motor shall be maximum 20 deg C (As per IS 12615:2011,CL No 4.3) higher than the permitted temperature rise at nominal voltage, frequency and temperature. The motors are to be manufactured for satisfactory performance under the following conditions and input supply characteristics /specifications:
(a) Rated voltage : 380V, 415V or 440V
(b) No of phases : 3(Three) Phase, 3(Three) wire supply system
(c) Voltage Tolerance
(i) Steady state : + 0.5% at all load.(ii) Voltage range : 15% to + 10%(iii) Recovery time : 1 second. (One second)
(d) Frequency
(i) Nominal frequency : 50 Hz or 60 Hz.(ii) Constant load tolerance : + 0.5 Hz or + 1.0%(iii) Load range tolerance : +1 Hz or + 2.0%(iv) Transient : + 2.5 %(v) Time of recovery : 2 Sec to within 1% of transient(vi) Frequency range : +/ 3%
(e) Cooling : Air Cooled
(f) Enclosure : IP 56Motors installed below deck IP 57Motors installed on weather deck IP 58Submersible motors upto 10 mtrs. IP 68 Submerged beyond 10 mtrs.
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(g) No of Poles : (As specified in SOTRs)
(h) RPM : (As specified in SOTRs)
(j) Frame size : Scope of Appendix ‘(E)’has been enhanced to include motors capacity up to 350 KW as against the earlier upper limit of 110 KW.
(k) Frequency at rated load
: 50 / 60 Hz (As specified in SOTRs)
(l) Power factor : 0.7 lagging upto 5 KW for 2/4/6 pole motors. 0.8 lagging above 5 KW for 2/4/6 pole motors. For motors with lower RPM (8Pole, 10Pole, 12Pole, 16Pole, 20Pole, 24Pole & 32Pole) as well as motors for multispeed the value will be as per agreement between manufacturer & purchaser
(m) Rating : Rating of motor shall be normally continuous rating. Only for specific application short term rating will be specified in SOTRs/TSP documents
(n) Bearings : Suitable bearings meeting the specifications mentioned at para 0554 of section V to EEDQ 71(R4) be provided at both driving and nondriving ends.
(p) Efficiency : Motor should conform to efficiency class IE2(High Efficiency) as per IS 12615: 2011: For motors with lower RPM (8Pole, 10Pole, 12Pole, 16Pole, 20Pole, 24Pole & 32Pole) as well as motors for multispeed the value will be as per agreement between manufacturer & purchaser
Environmental Conditions
0509. The design of the Motor is to catered for the most adverse of the environmental and ambient conditions. The AC Motor and control equipment shall conform to the following specification:
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Ambient temperature : 0 to 55 deg CRelative Humidity : 30100% at 35 deg C.Ship Motion : LIST 30 deg
ROLL + 30 deg PITCH + 15 deg
Shock and Vibration Requirement
0510. Motors are to be designed to withstand their full shock levels without allowing for the protection afforded by shock mountings.
0511. Motors shall comply with either of the following shock standards to be stipulated in the SOTR.
(a) Indian Naval shock grade curve “A” or NSSI (Appendix ‘C’) in conjunction with BR3021. All motors which affect the ship’s combat efficiency come under this category.
(b) Indian Naval shock grade curve “B” or NSSII (Appendix ‘D’) in conjunction with BR3021. All motors which do not affect the fighting capability of the ship come under this category.
0512. In general, the shaft deflection under designed shock and acceleration shall not exceed the airgap dimension.
0513. Motors shall be capable of withstanding forced vibrations within the range of 5 to 33 Hz for major warships and 7 to 300 Hz for minor warships and other naval ships/crafts built in accordance with society’s rules and regulations. Precautions must be taken against vibration excited by any attached driving or driven machinery having reciprocating parts.
0514. The fixing position for shock vibration mountings are to be such that the height of the machine center of gravity above the plane of fixing does not exceed one half of the minimum span of the mountings.
Design and Performance
0515. Unless otherwise specified in the Statement of Technical Requirements (SOTRs), motors are to be suitable for operation on 380V, 50Hz, 3 phase/415V, 50 Hz, 3 phase or 440V, 3 phase, 60 Hz supply depending on the main power supply of the ship.
0516. Where possible the dimension of the motors are to be in accordance with IEC 600721 / IS 1231 for foot mounting & IS 2223 for flange mounting motors.
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0517. Where motors are to be integrated with driven component, e.g. pumps, blowers, winches, etc. the Statement of Requirement will specify that a minimum margin of 7.5% should exist between the motor’s output and input power.
0518. A preferred range of AC motors known as standard range of motors has been developed for use in IN ships and is to be used whenever possible. Details of the range of motors are given at Appendix ‘G’. Where the preferred range of motors does not meet a particular requirement the motor manufacturer is to submit proposal for an individual design to meet the requirements in the SOTRs based on this EEDQ.
0519. All 3 phase motors are to be star connected and be provided with suitable starter/controller as specified in the SOTRs. Starter/controller to be used with a motor be selected from Appendix ‘G’ to EEDQ071(R4) based on the application.
0520. For 3phase motors the terminal markings, phase sequence and rotation are to be strictly in accordance with IEC 600348. In case of motors designed for rotation in either direction (fitted with bidirectional fans) the clockwise direction is to be obtained by connecting U, V, W to A, B, C in accordance with IEC 600348. Reverse direction can be achieved by reversal of one pair of the supply connections. See NES 627 for direction of rotation arrow. The direction of rotation is that observed when facing the drive end.
Operating Conditions
0521. The motors shall be capable of developing specified rated output at extreme conditions of ambient temperature, and frequency. While developing the rated output at extreme conditions of ambient temperature, voltage and frequency, the temperature rise of the motor shall be maximum 20deg C higher then the permitted temperature rise at nominal voltage, frequency and temperature. (As per IS 12615:2011,CL No 4.3,)
0522. Although horizontal motor will normally be sited in a fore and aft direction, they are unless other wise specified, to be capable also of operating with their shafts athwart ship. Axial flow and centrifugal fan motor are to be capable of operating with their shafts in any orientation.
Protection
0523. Motors need accurate and reliable protection at an economical cost. While the protection requirement for electric motor may seem straightforward, it would be incorrect to address this aspect in the same way for every application. Each application has its own requirements depending on the load, type of installation, environmental conditions and stability of power supply. Wide variety and technology in the field of starters exists and there is a need to select the right type of starters meeting the specific requirements. Where more accurate protection is necessary to protect personnel or machinery these are elaborated in detail in section 6 on starters.
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0524. All motors are to be provided with a means of protection from Voltage ranging 15% to + 10%. The protection system will be specified in the statement of requirements, and the cage rotor induction motors will generally consist of a type approved motor thermal protection system.
0525. The motor thermal protection system is to be designed to trip the motor out of circuit when the winding has reached the maximum safe temperature of the insulation.
0526. The motor thermal protection system must detect the occurrence of maximum temperature by means of Positive Temperature Coefficient Thermistors (PT CT). The PT CT are to be selected with reference temperature of 140 degree C for winding having class `F’ insulation and 180 degree C for class “H” insulation.
0527. A minimum of one PT CT is to be fitted in the winding of each phase.
0528. The PTCTs provided in each phase of the windings shall be connected in series and only one pair of leads shall be brought out to separate terminals in the motor terminal box. The PTCT leads are to be taped to the stator leads for support.
0529. If the protection system called for in the statement of requirement differs from the above clauses, full details of the system, components and the test will be specified in the statement of requirements.
0530. The crosssectional area of the connecting cables from terminals to the stator windings must not be less than the total crosssection of the winding conductor’s i.e., conductor X parallel paths.
0531. The gland to be provided in the motor terminal box for the motor thermal protection system is to be as per BS 6121/EN 6244402013 For double compression cable glands of Brass as per BS6121, with IP 67/68 Protection
0532. Full details of the system, components and tests are to be specified in the SOTRs if the required protection system differs for the foregoing.
Starting Current
0533. The value of starting current shall not exceed 7 to 8 times the full load current for motors of capacities up to 75KW and 4 to 5 times full load current for motors of capacities above 75KW. These values are applicable to direct on line starting only. No positive tolerance is allowable on starting current. For StarDelta/Reactive type starters, the starting current for motors with stardelta starters should not be more than 3 times of rated current. In order to limit the starting current values in line with standardised range of alternators on IN Ships, D.O.L starters shall be used for motors upto 15 KW rating.
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0534. If the requirement of Clause 0533 cannot be met with DirectonLine starting, proposals are to be submitted to NHQ/DEE for a soft starter, star delta type, or twostep starter of AutoTransformer type.
RunUpTime
0535. The run up time (total starting time) with the motor driving its driven equipment with the applied voltage at rated voltage is not to exceed 8 seconds. If it is not possible to meet this requirement, this is to be stated in the tender and the time and starting current proposed is to be given. Suitable schemes for starters and protection circuit is also to be provided in such cases.
0536. The runup time, with the motor driving its driven equipment with the applied voltage at rated voltage, is to be such that the starter will not trip when the protective devices, are set for normal operation at specified ambient temperatures
Locked Rotor Torque
0537. All motors must be capable of the specified locked rotor torque under the following conditions:
(a) A supply voltage of 85%, of rated voltage for the duration of the starting period.
(b) Maximum and minimum permitted steady state frequency limits.
PullOut Torque
0538. The pull out torque of all motors at rated voltage must not be less than 175% of rated load torque. (Note: Negative tolerance is not allowed on any specified torque mentioned above).
Over Speed
0539. All motors are to be designed to withstand, without excessive noise and vibration or damage, unloaded operation for a period of 15 minutes at a speed 15% in excess of the highest synchronous speed, i.e. the speed corresponding to the specified frequency plus the frequency tolerance of the supply.
Stall or Fault Conditions
0540. Under conditions of stall from ambient temperature with all 3 phases intact the stator warm up is to be such that PTCT protection should preferably operate within 70 sec. In the event of this being exceeded, it is to be declared at the earliest possible stage.
Over Loading
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0541. Motor, initially hot or cold and when connected to a supply at rated voltage and frequency, is to withstand without damage a locked shaft, or any other overload condition, for the maximum specified tripping time of the starter or for the operating time of a motor thermal protection unit.
Construction
Economy of Weight
0542. Electrical motor fitted in warships/crafts are subjected to very severe condition of shock and vibration and hence due allowance must be given to these factors in design. Economy of weight and size in all Naval vessels is of great importance and all manufacturers are required to keep this continually in view. As far as possible the dimensions of A.C. motors are to be in accordance with IS1231, IS2223 and IEC 600721as applicable.
Quality of Materials and Workmanship
0543. Various parts of the motor shall be made from the approved materials of the best quality/complying with the latest relevant Indian Standards/British Standards/IEC standards. If required, samples and test results shall be submitted for approval, before use. The workmanship shall be of the highest order and to the satisfaction of the Inspector.
0544. Enclosures of Motors. The type of the enclosure and where applicable, the method of cooling will be specified in the statement of requirements. Definitions of the enclosures normally called for are given in Clause 0545.
0545. The type of enclosures are:
(a) Drip Proof with Screen Protection. A motor that is constructed so that falling liquid or particles cannot enter the machine either directly or by striking and running along a horizontal or inwardly inclined surface, or being drawn in by the ventilating air in an amount likely to interfere with insulation or operation. The maximum angle at which liquid or particles may fall is 45 degree in any direction from the vertical with the machine in its normal altitude.
(b) Totally Enclosed. A motor that is constructed so that the free exchange of air between the inside and the outside of the motor is prevented, except that a permanently open inverted Tshaped drain, or other approved type drain, is to be fitted in the base.
(c) Water Tight. A motor that is constructed to withstand when stationery, immersion in fresh water to a depth of 1 meter above the highest point on the motor for two hours, without leakage or damage.
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(d) Watertight, Drained. A watertight motor fitted, after testing for water tightness, with an open inverted Tshaped drain, or other approved type drain in the lowest part.
(e) Water Tight, Drained, Fan Cooled. A Water tight drained motor fitted with augmented cooling by means of a shaft driven fan blowing air over the cooling surfaces and/or through the cooling passages, if any, incorporated in the machine.
(f) Submerged. A motor that is constructed to withstand continuous operation, starting and stopping when immersed in sea water to the specified depth or to the depth of 10 meters if not specified.
(g) Flame Proof. A motor that is constructed to comply with the requirements of IS/IEC 600790:2004 & IS/IEC 600791:2007.
(h) Flame Proof, Water Tight. A flame proof motor which is also capable of complying with the requirements for “water tight enclosure and comply with the requirements of IS/IEC 600790:2004 & IS/IEC 600791:2007.
0546. Ventilation And Cooling. Ventilation openings must not be made in the faces of the drive end shields of pump motors.
0547. Where a fan is necessary to maintain the ventilation of a motor, it shall be shaft mounted.
0548. The fan is to be designed to reduce air noise to a minimum. In order to achieve this the number of fan blades should not be equal to the number of poles or half the number of rolling elements in the bearings. Preferably an odd number of fan blades should be used.
0549. In all motors the fan shall be constructed separately from the rotor and shall be positively driven from the shaft. The fan is to be balanced whenever possible integral with the rotor and located so that it will assume an identical position on the shaft after any reassembly. The fans of motors are to be of cast/fabricated of MS/ Cast Aluminum construction. However, for specific motors of large capacities (e.g. Steering motors, Windlass motors etc) metallic fan blades, as recommended by the motor manufacturers/ specified in SOTRs, may be used. These metallic fans are to be treated with suitable chemical agents and are to be installed on the shaft with an unsalted bush, to avoid Bimetallic corrosion between the shaft and the fan. The fan, in no way should affect the motor performance.
0550. Stator and Rotor The laminated stator core is to be positively locked to prevent axial and rotational movement. The outer surface of the laminations must not form part of the enclosure.
(a) Cage rotors shall be cast in construction. Built up rotors with end rings brazed or welded to the bars in slots can also be permitted in specific cases. Cage materials shall be non brittle and resistant to salt, water and oil.
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(b) The rotor core assembly is to be positively located on the shaft and must not become loose under the action of fluctuating torque vibration etc.
(c ) The rotor core plate must be compressed axially between end plates and held rigidly in place. Axial, movement of the core assembly must be prevented.
(d) Adequate measures such as skewing of slots should be taken to prevent cogging or crawling. Where the reduction of noise is of prime importance, the slot should be skewed one slot pitch.
(e) Open or semi closed slots should normally be provided to facilitate easy repair, and the slot opening should be as small as possible consistent with the type of winding.
0551. Windings and Internal Connections
(a) All rigid and flexible conductors forming connections to or between windings are to be insulated using class `F’ insulating materials. Connections should be as short as possible and adequately supported against shock, vibration and faulty conditions.
(b) Where rectangular section conductors are used, they are to be in accordance with IS 1897. Corners are to be finished to the radius.
(c) The windings of stator and rotor shall be composed of form wound concentric coils or individual coils. Except for bar windings, each coil is to consist of continuous length of conductor without joints. Overhangs are to be adequately supported.
(d) Stator connection rings, where fitted, are to be sited at the nondrive end.
(e) Where called for, Hot spot temperature sensors are to be incorporated in prototype or first production motors, so that hot spot temperature can be sensed during type tests.
0552. Frame, End Brackets, End Shields and Terminal Box
(a) The Frame, End Brackets, End Shields and Terminal Box of motors are to be of cast or fabrication. If the aluminum alloy end shields are used, a steel ring is to be provided to form the bearing seating.
(b) Anaerobic liquid gasket or shellac compound is to be used for sealing bearing cap joints. Red or white lead must not be used.
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(c) The inspection windows of laminated safety glass are to be provided at the appropriate end or ends of slip ring motor, except where the ventilation opening of drip proof motor afford a convenient inspection facility. This requirement is waived where the largest possible window would be less than 40 mm Dia or 30 mm wide.
(d) The weight of the rotating parts of horizontal motors and the side load of vertical motor is to be transmitted directly to the frame and not through the bolts securing the end shield to the frame.
0553. Slip Ring. Slip rings are to be assembled on a sleeve positively driven from, and axially located on the shaft, with a provision made for the removal of the whole assembly as an integral unit.
(a) Each ring is to be insulated from the sleeve and from connection to other ring by resiglass tape.
(b) The slip ring is to be made from 4% cupronickel or gun metal to BS 1400.
(c) Slip rings of closed air circuit motor are to be in a naturally ventilated enclosure which excludes not the slip ring from closed air circuit.
0554. Bearings Housings And Shafts. As the type of bearings for a particular motor, depends on various design calculations, selection of type of bearings for both DE and NDE may be left to the manufacturer’s choice. However, for frame sizes up to 180, double sealed bearing (ie ZZ type) shall be provided, where no regreasing requirement will exist. For frame sizes above 180 regreasable bearing should be used. Further, the motor tally plate should indicate the DE and NDE bearing details, ie type, numbers, make etc so that all details will be readily available to carry out checks on bearings using shock pulse monitor. The motor manufacturers shall guarantee at least 40,000 working hours as the life of the bearings.
0555. Motors are to be designed so that the passage of any fatal electrical current through the bearings is avoided. The selection criteria of bearings are made as given below:
(a) Roller bearings should be selected from the preferred range of metric bearings. Housing design is to be such that any make of equivalent bearing can be fitted in service. Exceptionally, where interchangeable equivalent bearing of another make can not be fitted, details, together with reasons are to be submitted to DQA (WP)/DEE.
(b) Radial ball bearings of normal radial internal clearance designation should be used.
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(c) In single bearing motors a suitable bearing and bearing housing arrangement is to be provided which shall:
(i) Allows for some misalignment of the rotor to take place without adverse effect on the bearing.
(ii) Caters for any axial expansion of the rotors.
(d) In two bearing motor all axial loads must be taken by one bearing which is to be axially located. Preference is to be given to the use of ball bearing through out. The nonlocated bearing should be axially preloaded by a spring to minimise false brinelling and noise effects. (e) To ensure a long grease life the speed factor of grease lubricated bearing is not normally to exceed 75%. Speed factor is defined as the ratio of minimum machine speed to maximum speed at which the bearing can be used with grease lubrication. (f) Unless otherwise specified all roller bearings shall be selected to give a nominal running life of 40,000 hours under all specified normal conditions of operation and taking into account ship board vibration and any axial as well as journal loading on ball bearings.
(g) Standard roller bearing can operate for long periods at temperatures up to 125 degree C up to 150 degree C. Where it is not possible to provide suitable cooling arrangement and roller bearings will unavoidably be operating for prolonged periods at temperature exceeding 125 degree C consideration must be given to the use of heat stablised bearings.
(h) The static and dynamic load capacities of heat stabilised bearing are assumed to be 25% below values of similar standard bearing (operating temperature 125 degree C minimum). The calculated life and shock capacity of such bearing will always be correspondingly less than similar standard bearings. Therefore heat stabilised bearing should be used only when absolutely necessary and must not be used where standard bearing would be adequate.
(j) The inside of the bearing housing must not be painted.
(k) Care is to be taken in the selection of jointing materials to ensure that there is no reaction with the lubricant.
(l) All housings and shafts are to be adequately sealed to prevent lubricant exceeding, or foreign matter entering the housing.
(m) A shaft seal is to be fitted at the drive end of all pump motors on which the impeller is fitted directly on the shaft extension, to prevent ingress of moisture in to the housing. Shafts seals are to be of the single type in accordance with BS 1399 Part 1.
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(n) The outer bearing cover shall be an integral part of the end shield/ flange. The inner bearing cover shall be secured to the end shield/flange by screwing in externally hexagonal head bolts. To enable SPM test, suitable test point on uninterrupted metallic structure and are easily accessible be provided.
(p) All motors likely to come in contact in salt water, or operating in high humidity compartments are to be provided with AISI 431 material as per ASTM A47/ BS 970/ IS 1570 shaft material will be considered suitable for shaft of other motors. The shaft material is to be specified in the SOTR. Shaft for large motors, where specified, are to be forged.
(q) The shaft is to be designed so that no undue vibration occurs at any speed within the operating range of at the speed specified for the over speed test.
(r) The size and radiousing of bottom corners of any keyways must be in accordance with IS 2293:1974.The closed ends of keyways are to be tapered to zero depth or where this is impracticable, finished with semicircular ends.
(s) Tolerances on shaft and housing diameters are to be in accordance with IS 919 Part 1 and Part 2 and 2101.
0556. Lubrication. Unless otherwise specified, Grease type Lithon 3(Lithium Base) or equivalent as per IS 7623:1993 is to be used for roller bearings. The information about the source from where the above grease is to be obtained will be intimated by DQA (WP). The type grease should be chosen in such way that they are widely and easily available in the commercial market.
0557. Terminal Boxes, Cable Gland and Terminals. For ease of maintenance, the terminal boxes for all horizontal foot mounted motors are to be provided only on top of the motor body. For vertical mounted motors, the terminal box shall be provided on the side of the motor body.
0558. Where possible the terminal arrangements of top mounted terminal boxes are to allow for cable entry from either side of the terminal box and, if necessary gland on both sides are to be provided for this purpose. All cable entering the motor shall, except otherwise specified, be provided with double compression glands of Brass BS 6121/EN 6244402013 double compression cable glands with IP 67/68 Protection. 0559. Terminal boxes for submersible motor are to be water tight to the degree appropriate to the specified depth of immersion.
0560. Moulded terminal blocks are Dough Moulding Compound with good mechanical support as per IS 13411: 1992.
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0561. When cable clamps are necessary they are to be suitable for crimped cable sockets, soldered cable sockets must not be used.
0562. An external earthing terminal, of brass or stainless steel, is to be fitted adjacent to mounting point of every electrical unit of equipment. The contact surface is to be treated and provided with a nut and locking washer.
0563. Lifting Arrangement
(a) All motors weighing more than 20 KG are to be provided with either an eyebolts or any other approved means of slinging.
(b) All vertical motors whose rotors weigh more than 20 KG are to be provided with an approved means of slinging the rotor when in vertical position.
(c) The standards of Eye Bolts should be as per IS 4190:1984.
0564. Insulation
(a) Unless otherwise specified, all motors meant for fitment on Major warships are to be class `F’ insulated/Class H insulated as mentioned in the SOTRs. Class B insulated motors would however be considered for nonessential services of minor warships and other naval crafts.
(b) Insulating materials of lower temperature classification are not be used in contact with the windings and their use as support materials are to be kept to a minimum.
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SECTION VI
CONTROL GEAR (STARTER)
6. Preamble
0601. Introduction. The manufacturers of starters for ship based application should be ISO 9001 & ISO 14001 certified organisations, manufacturing majority of starter components viz. Contactors, MCCBs, intelligent Motor Protection Unit/Relays/Sensors themselves will be eligible to supply the control gear to the Navy. With regard to other vendors, who can be qualified for starters/control panels would require that the equipment be manufactured using components from IHQ approved firms. The firm must clearly indicate in the drawings make and PIL of all the components used in the starter/control panel. In addition to compliance to corresponding IECs and IS the starters should have successfully passed Technical Evaluation, Type and Environmental tests as per JSS 55555 and the vendors should be registered with NHQ/DEE and cleared by DQA(N)/DQA(WP).
0602. Methods of Starting. The starters using following conventional methods of starting AC motor capable of running up motors as defined in NES 632 at a sustained voltage of 85%rated value are fitted on IN ships:
(a) Direct OnLine. Supply voltage is directly applied at the motor terminals through simple switching device like contactor. DOL starting is the simplest & most economical method but has a drawback of very high inrush currents of the order of 68 times the Full Load Current (FLC). So the advantages of economy are offset by high cost in terms of increased maintenance and reduced life of the motor. The use of DOL starter is therefore to motors up to 10 KW rating.
(b) Reduced Voltage Starting, Due to the restrictions on high inrush current during starting and its adverse effects on the supply system and increase in maximum demand, etc., the motors of higher HP are generally started on reduced voltage using Star Delta Starter. The motor is first connected in star configuration and switched over to Delta configuration after a preset time. It is the first step towards reduced voltage starting but again similar problems are faced as in DOL, while changing over from star to delta, if 80% of the speed is not reached. Also when higher starting torque is required, use of Star Delta starter is not the best solution. The Star Delta starter to be used for motors beyond 10 KW ratings. Their applications to where soft starters cannot be used due to technical consideration or otherwise.
(c) Soft Starting. The limitations of above mentioned conventional starting methods are overcome by using Soft Starters which are thyristor based. The Soft starter gives a smooth & Stepless starting to squirrel cage induction motors by presetting starting torque, starting current and acceleration. The Soft starters reduce starting current surges and mechanical shocks reducing maintenance costs and increasing the life of the motor. The Soft starter optimally control the
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applied voltage for motor by varying the firing angles of the thyristors (two thyristors back to back in each phase) for achieving required starting characteristic. The correct values for Base voltage ramp time and limited current helps motor to get smooth, jerk less and stressfree starting. Since the motor torque behaves in proportion to the square of the applied voltage and the motor current in direct proportion, the accelerating torque & the starting current of the motor can be limited by controlling the effective value of the applied voltage. The base voltage is set to supply sufficient torque to achieve breakaway and the ramp time/current limit is adjusted according to the inertia of the load. The actual voltage applied to the motor during starting is a function of both load impedance and the thyristorfiring angle. During starting cycle when the motor reaches the rated speed and the applied voltage reaches to full value thereby allowing the motor to develop sufficient torque required by the load.
Design And Performance
0603. Electrical Supply Characteristics. Starters are to operate satisfactorily on 380/415V/440 V, 50/60HZ, 3PH 3 wire supply system. The characteristics of main AC supply voltage available in ships shall be as per the table given at Appendix ‘F’.
0604. Where an alternative supply is called for, a manually operated changeover switch is to be fitted before the starter. Where, in addition to Normal / Alternate supplies, there is a requirement for an Emergency supply; a changeover switch with emergency supply connection arrangements is to be fitted.
0605. A number of Standard Starter design for Surface Ships and Submarines have been developed and are to be used whenever possible (see BR 4540(601), (602), (603), (604) and section 6). Further, rationalized standard design incorporating Soft Starting techniques mentioned in this EEDQ to be utilised for Motors on Surface Ships.
0606. Where a Standard Starter design does not meet the requirements of particular system a special purpose starter should conform to SOTRs. These starters are to incorporate as many of the design concepts of the Standard Starter as possible.
The individual components of the starters should conform to the relevant IEC and IS applicable for respective products. However, in addition to the basic standards, typical samples of assembled starters will also have to clear various Type /Routine tests as per this specifications and environmental tests as per JSS – 55555. The starter system should consist of motor starter with following associated components to have reliable functioning and all the protections mentioned in clause 0614:
(a) Main incomer switchdisconnector fuse/MCCB of SCPD unit for isolation purpose.
(b) HRC fuses for motor, cable & switchgear protection against short circuit.
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(c) Line contactor for physical isolation (ON/OFF either from local or from remote) under operation of protection system.
(d) Intelligent microprocessor based Motor Protection Unit for Comprehensive protection.
(e) Ultra fast acting semiconductor fuses for thyristor protection (applicable to thyrister based soft starters).
(f) Bypass contactor for bypassing the controller during normal run condition (to improve the life of the thyristors).
0607. For any AC starter parameter not specified by this EEDQ or by NES 501/636, IS 13947 part 4 is to apply.
0608. All starters will normally be used for single direction of rotation unless otherwise specified in the Statement of Technical Requirements (SOTRs).
0609. Soft starters should also be capable of providing torque control (useful only for specific drives) where the load during starting changes very frequently and drastically. It is effective only where the drive requires a linear ramp curve (change in rpm with respect to torque is a constant ratio) irrespective of the load connected to it. These are optimum solution for motors above 15 KW, where speed variation is not a necessity. Selection of soft starters be governed as standardised in appendix ‘G’ to EEDQ. Soft Starters are to be provided for motors of 15 KW and above ratings with capability to:
(a) Ensure smooth & controlled starting of the motor.
(b) Reduce the starting current of the motor to 24 times the rated current, depending on connected loads.
(c) Reduce “peak load” demand on the generator (during the motor starting)
(d) Eliminate the problems associated with stardelta starting e.g. fuse blowing during star to delta changeover.
(e) Provide controlled smooth stop helps to eliminate “water hammer effect” in the pumping systems.
(f) Reduce the wear & tear of the transmission system e.g. pulley, belt etc.
(g) Enhance the bearing life of the motor as well as the driven equipment.
(h) Compact & lightweight.
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0610. The starter should ensure continuously increasing torque just in excess of the load torque as shown by the curves of speed against torque characteristics by adopting one of the above starting methods.
Protection.
0611. Important motors above 15 KW rating should be incorporated with microprocessor based intelligent device MPU which can perform metering, protection, control and communication functions during starting and running. Further, all starters integrated with Power Management System, and/or Integrated Platform Management System (IPMS) will have serial communication link and following protections:
(a) Overload(b) Unbalanced current (phase imbalance)
(c) Single phasing(d) Thermal protection.(f) Short circuit protection(g) Too many start(h) Stalling(j) Start inhibit
0612 Motors of rating below 15 KW and not interfaced with APMS should be integrated with DOL/stardelta starters as specified in appendix ‘G’ to the EEDQ071 (R3). These motors be protected against following faults:
(a) Overload(b) Unbalanced Current (c) Single phasing (d) Thermal protection.
(e) Locked Rotor
0613. All motors integrated with Automated Power Management System (APMS) on board ships should have coded MPUs for watchdog functions to monitor health state of hardware and software. Further, the protection functions should also have different options of resetting such as AutoReset or HandReset.
0614. The MPU should be of rugged construction. In addition to the assembled intelligent starter successfully passing JSS 55555 tests, the MPU should independently comply vibration, shock and bump classes as per IEC 6025521.
0615. The most common cause of over current is an excessive load on a machine and this may be due to a blocked pump, jammed fan, seized bearing or simply exceeding the capabilities of the machine. If this overload condition is not detected quickly, permanent damage to the motor may result. Undercurrent is usually caused by the load being disconnected from the machine. This is often the result of a mechanical failure such as the breakage of a drive belt, shear pin or gearbox and could have serious implications, if left undetected. The above conditions should be
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detected accurately by current sensing device/relay and trip the motor starter in the event of undercurrent /over current situations
0616. Incorrect phase sequence can cause serious mechanical damage by allowing the machine to run in reverse. Whilst the complete loss of a phase may allow a machine to run, if left undetected, the motor could be damaged due to built up heat. The starters should incorporate phase sequence and loss of phase monitoring protection for detection of these conditions immediately and disconnecting the supply in less than 3 sec to prevent damage to the motor or connected machinery.
0617. The temperature sensing thermistors embedded in the motor windings monitor the actual temperature in the winding rather than simulating it by some external means. The starter should interrupt the motor supply on receipt of the signal from the thermistor, when the temperature crossing the upper limit.
0618. Protection of motor and associated power circuit, including cables, requires proper consideration for different abnormalities. In the event of an overload, the equipment is protected by an overload relay with certain time delay. But, in case of a short circuit, the current needs to be interrupted quickly for restricting the letthrough energy and consequent damage to the downstream equipment. This needs proper coordination between Short Circuit Protective Device (SCPD) and downstream equipment.
Type of CoOrdination
0619. The starter should incorporate type 2 Coordination as per IEC 6094741/ IS 13947 (PART 4/SECTION 1) under shortcircuit conditions. Type2 coordination considered economical in the long run has a major advantage of contactor or starter safely clearing the short circuit, causing no danger to persons or installations and shall be suitable for further use. Light contact welding is accepted. After the fault is cleared, the user needs just to reset the breaker or replace the blown fuse and check for contact welding.
0620. The only way to ensure Type 2 coordination in the starters is to carry out exhaustive tests of the particular fuse & relay or MCCB & relay combinations with the contactors. While individual protection devices may perform to a given set of characteristics, their behavior in combination affects the way the circuit reacts to a fault. Selection of equipment becomes very important here. Sometimes all the devices are not available from a single manufacturer. For e.g. if the fuse/MCCB manufacturer does not make relays or contactors one has to depend on other makes to offer complete protection system. It is likely that the relay or the contactor undergoes some design changes, which can affect the selection combination with the fuse/MCCB. Thus it is very important that all protective equipment are available from a single source to offer proper coordination.
0621. A chart giving component ratings for different ratings of motors, compliant with Type 2 coordination is given in Appendix J. For given fuse/MCCB and overload relay combination, the contactor rating specified is minimum.
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Short Circuit Protective Devices (SCPDs):
0622. Fuses Fuses are traditionally used as SCPDs because of their low initial capital cost and capability to interrupt faults faster. Fuses have excellent current limiting characteristics and can be applied safely on systems having high fault levels. Fuse is able to restrict letthrough energy at high fault levels. At high current, the fuse element melts (prearcing period) followed by arcing which persists until the resistance across the fuse builds up to reduce the current to zero (arcing period). Both these actions take place very quickly. The combination of highspeed operation and high arc resistance limits the peak fault current, thereby minimising the letthrough energy. The following factors are to be considered while selecting a fuse:
(a) The fuse should not blow during starting of the motor.
(b) The fuse should blow at a current lower than the breaking capacity of contactor selected.
(c) The fuse should blow at a current at which overload relay, contactor and cables are capable to handle the letthrough energy.
MCCBs
0623. Use of current limiting MCCBs be considered in the starters. In the event of a fault, these MCCBs operate quickly, much before the short circuit current reaches its peak value. The following factors to be considered while selecting an MCCB for this purpose:
(a) The thermal rating of MCCB should be greater than the motor full load current.
(b) The breaking capacity of the MCCB should be greater than or equal to the prospective fault current at its installation point.
(c) The magnetic threshold setting of the MCCB should not result in nuisance tripping during starting of the motor.
(d) The current limiting MCCB should be used with only magnetic protection (without thermal protection) and a suitable thermal overload relay with matching motor characteristics to be provided for overload protection.
(e) The thermal characteristics of MCCB (if provided) should be such that it falls above the overload relay characteristics up to the magnetic threshold of the MCCB.
(f) The contactor should be able to break currents up to the magnetic threshold of the MCCB.
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(g) The starter should be able to withstand letthrough energy of the MCCB.
MPCBs
0624.Type approved MPCBs could also be considered for fitment in Energy Distribution Centres (EDC) in lieu of MCCBs up to 63 amperes rating if power supply is required to be connected to individual motor. Use of MPCB will obviate requirement of starter however, a three phase contractor in conjunction with ON/OFF push buttons will be required for start/stop functions. All the necessary protections shall be incorporated in such MPCB. Such MPCB should be able to withstand system let through fault current.
0625. Magnetic Threshold. It is essential to determine magnetic threshold for selection of suitable MCCBs to prevent nuisance trip during changeover from star to delta. For example, in stardelta starters, at starting, the starting current is reduced to 1/3 of that with DOL starters. But, at the instant of switching from star to delta, a high current peak lp is experienced. It may shoot up to 18 times the normal current depending on the speed of motor at the instant of changeover. To reduce such high pick value, the changeover time for start to delta is to be properly selected.
0626. However, this changeover takes place in a very short period of time. So, it doesn’t affect the selection of the back up fuse. However, MCCBs being peak sensing devices may cause nuisance trip during the changeover between star to delta, if it is not properly selected.
Selection of Equipment
0627. Selection of equipment becomes very important here as individual protection devices may perform to a given set of characteristics, their behavior in combination affects the way the circuit reacts to a fault. Sometimes all the devices are not available from a single manufacturer. For e.g. if the fuse/MCCB manufacturer does not make relays or contactors he has to depend on other makes to offer complete protection system. It is likely that the relay or the contactor undergoes some design changes, which can affect the selection combination with the fuse/MCCB. Thus it is very important that all protective equipment are available from a single source to offer proper coordination or such tests are to be carried out periodically.
Selection of Starters.
0628. A standardised range of starters given at AppendixG is to be used for selection for motors for various services/equipment fitted on IN ships. AppendixG provides general guidelines for selection of type of starters. However, if technically it is found to be unsuitable for any particular requirement, the sponsor is to be informed in writing of the circumstances with a copy to Directorate of Electrical Engineering, Naval Headquarters, New Delhi for any deviation/ clarification.
Contactors.
30
0629. The contactor should be able to withstand the let through energy of Short Circuit Protection Device (SCPD) and break any current up to the magnetic threshold of the MCCB. It should withstand the full load current continuously for the utilization category (AC3, AC4 etc. as per IEC 60947/IS13947) specified. The contactors shall generally be in accordance with IEC 60947 Part 4 and conforming to following technical requirements / specifications:
(a) The mechanical life is to be between 310 million operations and the class of intermittent duty is to be Class 1 i.e., up to 120 operating cycles per hour as a minimum.
(b) Contactors are to be front connected.
(c) The main contacts are to be made of silver cadmium oxide or copper faced with silver cadmium oxide. Butt type contacts are preferred and are to be readily removable.
(d) Contactors are to have inherent low voltage protection and must not open the circuit until the voltage has dropped to below 65% rated voltage.
(e) The minimum voltage at which contactors must pull into the fully operated position is to be not greater than 85% rated voltage.
(f) Contactors are to be inherently shockproof to the appropriate shock grade specified in the SOTR for the starter down to 85% of rated voltage. When the starter is in the off position the main contacts must not close under shock.
(g) Contactors are to have the facility for at least four sets of auxiliary contacts. These could be of any combination of N/O or N/C contacts.
(h) Contactor coils are to be easily replaceable.
(j) The Utilization Category is generally to be AC 3 as specified in IEC 60947 Part 4 (starting and switching off during running of squirrel cage motors), but where significant risk of trip exists during start or repeated stops and starts are necessary such as for cranes etc then the category is to be AC 4 (starting, inching and switching off during starting of squirrel cage motors).
(k) Each contactor is to be type approved by NABL accredited test house for a fault level of 50 KA. Negligible contact burning or contact welding is to take place.
(l) For dual speed starters, contactors are generally to be mechanically and electrically interlocked.
(m) For specific ships, the fault level will be higher than 50KA, the SOTR will define the fault levels, which the contactor/starter/Switchgear will withstand.
31
Relays
0630. The relay range is selected according to the phase current as the relays are connected in phase circuit. Another important factor is that the relay used should be able to withstand the letthrough energy of the respective MCCB. Hence, in some cases, CT operated relays may have to be provided even in case of small motors.
MCCBs
0631. In the current limiting MCCBs, the magnetic current setting is 12 times the nominal current. But in StarDelta starters, the current may shoot up to 18 times during changeover from Star to Delta. The nominal rating of the MCCB chosen should therefore be 1.5 times or above the line current of the motor where these are used in conjunction with Star Delta starters.
Special Starters
0632. Special starter is to be provided when operational requirements precludes the use of standard starter. Following features (to be specified in SOTRs) are to be included in special starters for specific services:
a. Automatic control.
b. “Motor Tripped” Alarm.
c. “Overheat “warning.
d. “Tripped on Overheat” indication.
e. Limitation on starting current.
f. Starters with watertight or flameproof enclosure.
g. Starters with controls and indication separated from starter enclosure.
Component Selection
0633. Components for use in Standard Starters for Surface Ships are to be selected from LCSO/DQA (N) approved list of components. Special Starters are to be designed to use, as far as possible, components whose specification complies with NES 501, NES 538 and NES 581 are to be used. Such components may require evaluation as to their fitness for purpose. All ferrous components including springs are to be treated to prevent corrosion. Make and type of components are to be listed in the binding drawings.
Internal Wiring.
0634. Only LFH (Limited Fire Hazard) cables are to be used for internal wiring.32
Push Buttons/Indicators
0635. When indicator lights are called for on an equipment panel they are to be generally in accordance with NES 501 Section 8. The requirements of NES 599 and NES 626 are to be taken into account. Indication lamps used shall be of neon/LED cluster type.
0636. Local indicator lights are to be coloured as follows:
(a) Power on White or Clear(b) Motor running (Fast or Slow) Green(c) Auto Mode of Operation Amber (If applicable)(d) Motor Trip Red. Common Indication for all
types faults(e) ‘START’ Push button Green(f) ‘STOP’ Push button Red
0637. Remote Control. Care is to be taken when the starters interface with the remote control system of the ship or submarine. The use of the contactor coils circuit for remote monitoring is to be avoided. The use of the auxiliary contacts on the contactor or auxiliary relays is preferred.
0638. Automatic Control. Starter used for ventilation motors to be provided with the facility for automatic start on restoration of power supplies after interruption of power if it was `ON’ at the time of Interruption. Such starters will have to incorporate auto restart feature to provide requisite command after restoration of supplies.
CONSTRUCTION
0639. Enclosure. The enclosure of starter shall be fabricated of mild steel sheet (SWG14), drip proof construction (up to 60 deg from vertical) The type of enclosure required is to be specified in the SOTR and is to be in accordance with NES 501 Section 13. Standard starters and most special starters are required to be totally enclosed and splash/spray proof whilst for some application watertight equipment (to be specified in SOTRs) is called for. The details of the mechanical design requirements of the enclosure are also contained in NES 501 Section 13.
0640. Enclosure Protection. IP55.
0641. Shock Standard. Naval shock standard NSS GRADE ‘A’ or `B’ (as specified and applicable as per Appendixes ‘C’ or ‘D’) in conjunction with BR3021.
0642. Vibration Standard. 533Hz (conform to specification JSS55555)
0643. Insulation. Class – F or of higher grading.
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0644. Shock Mounts. The shock mounts required are to be supplied along with the equipment. Quantity and pattern no. of shock mounts are to be indicated in the drawing.
0645. Earthing. Earthing and bonding is to be in accordance with NES501 section16. An external earthing terminal is to be provided at both sides of the item. Hinged cover of starter is to be earthed with fixed part of the starter. This is to be done within the starter with 2.5 Sqmm copper earth wire connecting earth stud with starter enclosure using lugs.
0646. Overall Dimensions . Overall dimension and weight of the starter is to be kept as minimum as possible.
0647. EMI/EMC. The equipment shall be designed to meet the EMI/EMC standards confirming to specifications MILSTD461E/F.
Material and Finish
0648. Materials and Finish are to be normally in accordance with NES 507 are NES 1005. Finish colour, unless stated otherwise, for all starters is to be Pebble gray, RAL 7032 epoxy power coated. Standard specification and grade of material of each component used to be indicated in the binding drawings.
0649. Painting. As specified in SOTRs. if not specified in SOTR should be Pebble gray, RAL 7032 epoxy power coated.
Tally and Diagram Plates
0650. All tallies and diagram plates shall be of anodized aluminum alloy.
0651. Diagram plate indicating detail of connection is to be provided and affixed on rear of the starter cover.
0652. Size of tally plate, diagram plate, danger plate etc. and their letters shall conform to specification NES723.
0653. 415 Volts Danger Plates is to be provided on starter.
Terminals.
0654. Bolted type terminals and crimped socket of electrolytic copper are to be provided for all incoming and outgoing cables and are to be supplied along with the main equipment.
0655. All remote control/internal wiring in starter should be terminated using bolted type terminals for cable end termination.
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0656. Adequate space is to be provided inside the starter for bending and termination of incoming and outgoing cables.
0657. Cable Entry Glands. For cable entry brass glands shall be used as per BS 6121/EN 6244402013 double compression cable glands of Brass, with IP 68 Protection. Cable glands are to be supplied along with the equipment.
0660. Heaters. An approved type of nonluminous low temperature heater shall be fitted inside the starters installed in compartments having humidity (to be specified in SOTRs) to prevent condensation when the equipment is not running. The heater(s) shall have sufficient rating to maintain the air temperature within the machine enclosure not less than 5 deg C above the out side ambient air temperature. This shall be fitted preferably at the bottom portion of the starter. The tubular form of construction is preferred. Anticondensation heaters are to be arranged to be fed from a separate supply at 230 volt, 50Hz, single phase, and are to be so connected that they are `OFF' when the equipment is operating, but are automatically switched `ON' when the equipment is switched off. A lamp indication is to be provided marked `CONDITIONING HEATERS ON', and a yellow warning marker plate is to be provided stating `CONDITIONING CIRCUIT LIVE WHEN EQUIPMENT OFF'. Lamps are not required for illumination in starters.
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SECTION VII
INSPECTION AND TESTING
0700. Inspection. DQA (WP)
Tests/Type Testing and Inspection.
0701. Type/ Routine Testing. The motors and starters are to under go type testing within three months of the placement of order, if not tested earlier. All tests required are to be carried out as specified in this section and report submitted to IHQ MoD (N) DEE
0702. General . All tests are to be carried out on rated conditions except where otherwise specified. The various tests required to be conducted on motors/control gears as part of type tests and routine tests are mentioned at Appendix ‘H’ to the EEDQ071(R4).
0703. In certain cases test figures are required to be quoted in handbooks for guidance during maintenance and repair.
0704. Classification of Tests. Motors and Starters will be subjected to the following tests as applicable.
a) Performance/Type Testsb) Routine Testsc) Acceptance tests d) Environmental Tests
0705. Performance Tests. These are type tests carried out on each design, at manufacturer’s works. The first motor of each design is to be subjected to performance tests/type tests at the manufacturer’s works to demonstrate that all the specified requirements have been met.
0706. The performance tests which are required to be carried out are described in the following clauses of this section.
0707. Starting current and runup time. Calibrated oscillograph records are to be taken showing the line current, line voltage, and runup time from the instant of starting until the line current falls to its steady running value.
0708. The tests are to be carried out both with the motor unloaded and with the motor coupled to the driven machine, starting under simulated loading conditions of service with which it will be used.
0709. The records are to be taken with both 100% and 85% rated line voltage at the upper limit of frequency tolerance maintained at the starter input terminals during the runup period.
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0710. Starting Torque. The starting torque or locked rotor torque of motors is to be determined with the rotor locked at the rated voltage. The locked rotor torque must not be less than that specified by the manufacture of the driven equipment. Unless agree otherwise, the starting torque shall not be less than 1.5 times rated value at normal volts for motors of 50 HP and above.
0711. Pull Out Torque. The pull out torque is to be measured at rated voltage and must not be less than 175% of rated load torque.
0712. Temperature Rise Tests. Continuously rated S1 motors are to be subjected to a temperature rise test at rated load when supplied at rated voltage and frequency, which is to continue for six hours or until the temperature rises of the various parts of the motor have been constant for one hour.
0713. The temperature rise measurement will be carried out as per IS 12802:1989. The duration of temperature rise test for short time ratings (Duty type S2) is that given in the rating. For periodic duty type ratings (Duty type S3 to S8) , the load cycles specified shall be applied & continue until practically identical temperature cycles are obtained. The criteria for this are that a straight line between the corresponding points of duty cycles has a gradient of less than 2°C per Hrs or the test shall be performed as per IEMA3:1978.
0714. The tests for rise in temperature in motors is to be carried out with alternating current of full load value at an average frequency not below 95% of the rated frequency.
0715. Unless otherwise specified the test is to be carried out at normal room temperature. The temperature rise is to be measured by one of the methods given below in accordance with IS 12802:1989. When the temperatures are required to be measured in varying or moving magnetic fields, the thermocouple or resistance method is to be used to avoid inaccuracies which may result from the heating effect of eddy currents on Mercury thermometers.
(a) Thermometer Method. A Mercury or alcohol bulb thermometer is to be used. The bulb of the thermometer is to be placed in contact with or as close as possible to the part, the temperature of which is to be measured. The exposed part of the bulb is to be covered with cotton wool or similar heat insulating material. The temperature is determined by thermometers applied to accessible surfaces of completed motor. The term ‘thermometer’ includes not only thermometers, but also non embedded thermocouples and resistance thermometers. When bulb thermometers are used in places where there is a strong varying or moving magnetic field, alcohol thermometers shall be used in preference to mercury thermometers.( Ref IEC 600341 CL. NO. 8.5.4) (b) Thermo Couple Method (Embedded temperature detectors). The thermocouple is to be embedded or attached in an approved manner to the
37
equipment in accordance with IS 325. When applied to the surface of a contact or conductor, the hot junction is to be wrapped with metal foil and covered with electrical insulating material. The thermocouple circuit is to be earthed to minimize the possibility of capacitance effects. The temperature is determined by means of temperature detectors ( eg resistance thermometers, thermocouples or semiconductor negative coefficient detectors) built into the motor during construction, at points which are inaccessible after the machine is completed.( Ref IEC 600341 CL. NO. 8.5.3)
(c) Self Resistance Method In the self resistance method, the temperature rise of conductor is determined by the increase in resistance of the conductors. The temperature of the conductor is to be cold and from initial temperature of the equipment. The temperature of the conductors, measured before the start of the test is not to differ from that of the surrounding medium. The temperature of the winding is determined from the increase of the resistance of the windings.( Ref IEC 600341 CL. NO. 8.5.2)
0716. Temperatures are to be taken at half hourly intervals during the test. Measurement of final temperature is to be carried out in accordance with BS 4999 Part 32 or IS 12802:1989.
0717. Limits of permissible temperature rise for the parts of the motor is shown in table 1 section 5. These temperature rise are based on the ambient temperature of 55 degree C.
TABLE1
(Limits of permissible temperature rise for parts of the motor)
Part Method Temp rise in deg CClass F
Temp rise in deg C class H
Remarks
Stator Windings
Resistance
85 110
Slip rings Thermometer75 110
Permanently short Circuited insulated Winding.
Thermometer
85 110
Permanently short Circuited Uninsulated Winding.
The temperature rise shall in no case reach such a value that there is a risk of injury to any insulation or other Material on adjacent parts.
Iron cores and Thermometer 85 105
38
other parts in contact withinsulated windingsBearing cap Thermometer
60 85
0718. Efficiency. During the final stage of temperature rise tests, when temperature are steady necessary measurements are to be made to enable the efficiency of the motor under test to be calculated at rated load.
0719. Hot spot sensing. Where hot spot sensing is called for, hot spot measurement is to be carried out during the temperature rise tests for motors of 50HP and above.
0720. Routine Tests . All motors are to be routine tested. The routine tests which are to be carried are described in the following clauses of this section.
0721. NoLoad. The no load current, power factor and speed of the motor are to be measured at rated voltage.
0722. Over Speed. Motors are to be run unloaded for a period of 15 minutes at a speed 15% in excess of the highest synchronous speed and the value of the over speed recorded.
0723. Winding Resistance. The resistance of winding is to be determined, in both hot and cold condition. The resistance of the conductor of all circuits, where it is 0.1 ohm or greater, is to be measured by means of a Bridge megger or its equivalent. The resistance of the conductor of all circuits where it is less than 0.1 ohm is to be measured by means of an approved apparatus based on the comparison of potentials and capable of indicating differences of 1 percent in the resistance under test.
0724. Withstand Voltage Test (High voltage test). These tests are to be carried out as enumerated in the following clauses. When testing the thermistor protection system, the testing points are to be:
(a) Between both motor terminals and thermistor terminals connected together and the motor case.
(b) Between the thermistor terminals connected together and the main winding terminals.
0725. Policy on With Stand Voltage Test. A withstand voltage test a.c. is to be used for equipment designed for earthed or unearthed systems where the nominal voltage of supply does not exceed 700 Volts.
0726. Withstand voltage test are to be applied once only at the full specified test voltage. Additional withstands voltage test, if required, are to be carried out with a
39
test voltage of 80 percent of the specified value. When it is required to carry out an additional withstand voltage test on an assembled group of items which previously and individually have passed their withstand voltage test, the test voltage to be applied is to be limited to 80 percent of the lowest test voltage appropriate to any one item.
0727. Standard Withstand Voltage Test The withstand voltage test is carried out by means of a source of alternating current, whose waveform on open circuit is approximate to a sine curve having a voltage which equal to that specified in clause 0737 of this section.
0728. The test shall be commenced at a voltage not exceeding half of the full full test voltage.The voltage shall then increased to full value, steadily or in step of not more than 5% of the full value, the time allowed for the voltage increase from half to full value being not less than 10 second. The full test voltage shall then be maintained for 1 min. There shall be no failure during this period
0729. Normally all inspection and access covers of the equipment are to be kept in position during the test.
0730. A test voltage, as specified below, shall be applied between the windings under test and the frame of the machine, with the core and the windings not under test connected to the frame. It shall be applied to only new and completed motor with al its parts in place under conditions equivalent to normal working conditions and shall be carried out at manufacturer’s works. When the thermal tests is carried out, the withstand voltage shall be carried out immediately after that test. During the routine testing of quantity produced motors up to 200kw, the 1 min test may be replaced by a test of 1 sec at 120% of the test voltage specified in 0734.
0731. The test voltage is to be applied for the specified period between those parts of the motor at earth potential and all conducting circuits intended to be insulated from earth.
0732. The conducting circuits are then to be reconnected to form a number of groups, each group consisting of the circuit normally connected to one pole of the A.C. supply. The test voltage is to be applied for the specified period between earth and each group in turn, the other group being connected to earth.
0733. During the test the equipment is to be kept under continuous observation. Break down of any insulation or flashing over, because of insufficient leakage paths is to constitute failure of the equipment under test.
0734. The test voltage to be applied for the motor/starters are as follows:
Motor Test Voltage
40
Motor having an electrical Loading below 3 watts per r.p.m
1 KV plus twice working voltage
Motor having an electrical Loading of 3 watts per r.p.m and above
1 KV plus twice working voltage with a minimum of 1.5 KV.(Ref IEC 600341 cl 9.2 table 16).
Starters and control gears 1 KV plus twice working voltage.with a minimum of 1.5 KV. .(Ref IEC 600341 cl 9.2 table 16)
0735. Insulation Resistance. Tests for insulation resistance are to be carried out as indicated in clause 0739 of this section. The insulation resistance of motor is to be measured in both the hot and cold conditions. The test must include measure of resistance for the thermistor protection system. The test must be carried out with the same test points as stated in clause 0738 of this section. The test voltages is to be 500 volts.
0736. Measurement of Insulation Resistance. This test is to be carried out on all motors (both before and after withstand voltage test) in the same manner as the withstand voltage test as regards the methods of connecting the various circuits for the application of voltage and the period of application of the test voltage is to be one minute unless there are indication of fault insulation. In this event, the application of the test voltage is to be maintained for as long as necessary in order to determine the condition of the insulation.
0737. If the insulation resistance during the test falls to less than half of that obtained at the start of the test, or if there are sudden fluctuation in the reading of the instrument, the insulation of the motor is to be regarded as faulty.0738. The test for measurement of insulation resistance is to be carried out after the withstand voltage test.
0739. The insulation resistance of the motor is to be not less than 10 Megohms.
0740. Acceptance Tests These tests, establish the reliability of the motor from its construction and design from the point of view for acceptance. The acceptance tests which cannot be carried out by a firm, will be arranged by DWP/inspection authority at any of the DGI laboratories. 0741. Acceptance test which are required to be carried out are as follows:
(a) Noise level test.(b) Enclosure effectiveness tests.(c) Environment withstand tests.
41
(d) Vibration tests.(e) Shock or impact tests.(f) Bearing health check at No Load conditions
0742. Noise Level Test The overall sound power level in decibels must not exceed 90 db even at 20% over speed. In a sound proof nonreverberant room the sound level recorded by soundlevel meter shall not exceed at a distance of one meter from the motor. Chart mentioned for noise level for various speeds & ratings as per IS 12065:1987 & IS/IEC 6003414 is to be followed.
0743. Enclosure Effectiveness Tests. These tests are to be carried out in accordance with IS/IEC 6000345:2000. All motors except `water proof’ motors are to be tested for IP 56 protection, water proof motors are to be tested for IP 57 protection. Motors submersed upto 10 mtrs. are to be tested for IP 58 and those submersed beyond 10 mtr. to be tested for IP 68.
0744. Environmental Tests. These tests are to be carried out as per Joint Service Specification JSS 55555. One motor from each range is to be subjected to these tests and other frame size in the range shall be accepted on the basis of certification from DWP/DGI. The proto type motors and starters will be subjected to environmental tests as per table given below:
Sl TEST SPECIFICATION
TEST CONDITION/SEVERITY
(a Vibration JSS 55555 Test 28 5 – 33 Hz
(b) High Temperature JSS 55555 Test 17
55 deg C for 16 Hrs. Procedure 5, Test Condition ‘G’
(c) Damp heat JSS 55555 Test 10 40 deg C – 95 deg C RH for 16 Hrs
(d) Drip proof JSS 55555 Test 11 Vertical Water drip1 m height for 15 min
(e) Mould growth JSS 55555 Test 21 29 ° C 90 % RH mould growth chamber for 28 days
(f) Bump JSS 55555 Test 5 1000 bumps – 40 G, 6 m/sec
(g) Shock/Impact JSS 55555 Test 24 As per laid down specifications
(h) Inclination/Tilt CL 3.12 As per laid down specifications
(j) Ship MotionAs per laid down specifications
42
(k) EMI/EMC MILSTD 461 E/FAs per laid down specifications
(l) Performance/ Electrical
NES 629 Clauses 0401 to 0521
(m)Environmental Stress Screening
DQAN policy 6630/Policy17/DQAN/QA11 dated 15 Mar 12.
For PCB’s and Electronic Components
0745. Vibration Tests. When specified in the statement of requirement, vibration test is to be carried out in accordance with Joint Service Specification No. JSS 55555. The frequency range and amplitudes are to be as per clause 0513.
0746. Shock Or Impact Tests. Shock tests are to be carried out in accordance with Joint Service Specification JSS 55555. Motors shall comply with the shock standards as stated in clause 0511 of section 3. One motor from each range is to be shock tested and other frame size from the same range shall be accepted on the basis of shock calculation and design inspection.
0747. Combined Equipment Tests. Each motor is to be set up with it’s own starting, controlling and protective gear to drive, where practicable, the machinery with which it will be used in service. For motors with thermistor protection any starter which protects the motor during the tests may be used.
0748. Test Results. The test data obtained during performance tests of motors in factory premises be logged and following graphs be generated to evaluate the motor performance.
(a) Torque Vs Speed(b) Current Vs Speed(c) Current Vs Time(d) Efficiency Vs Output(e) Power factor Vs output
The results of the performance tests are to be compiled in to a report. The report is to include all oscillograph records taken during the tests and two copies each of the report are to be forwarded to DQA(WP) or the Inspecting Authority indicated in the contract, as soon as possible after the tests have been completed. In addition to the above, reports of all the tests (including performance and routine tests) giving the detailed record of the tests carried out should be forwarded in duplicate.
0749. If any motor fails to meet the specified requirement in anyway, it may be rejected, or at the discretion of the inspector, the faults may be rectified and the motor retested. The repetition of any tests to ensure that they represent the normal performance of the motor may be called for.
43
SECTIONVIII
DRAWINGS AND DOCUMENTATION
BINDING DRAWINGS.
0801. The following binding drawings in respect of motors and their control gear (starter) are to be submitted to NHQ/DEE for approval:
(i) Overall dimensions of the equipment.(ii) Mounting arrangement.(iii) CG of the equipment.
44
(iv) Winding and performance data sheet.(v) Part identification list, indicating part No, Quantity makers name, specification no. etc.(vi) Sectional assembly drawings.(vii) Motor terminal box diagram.(viii) Terminal connection and circuit diagram
0802. One set of binding drawings is to be supplied to the shipyard for their comments while forwarding to DQA(WP)/IHQ MoD(N) at the time of approval.
0803. Documents. The following documents are to be supplied along with the main equipment:
(i) Equipment technical 1 setmanual
(ii) Installation 1 setspecifications
(iii) CPL/PIL 1 set(iv) As fitted drawings:
Velographs 1 sets Paper prints 1 set
0804. All the documents must be properly filed/bounded and labeled.
0805. All the documents are to be prepared in accordance with specification JSS025101.
0806. The manufacturer should furnish following details for motor and their control gear (starter) at the time of tendering:
(i) Service(ii) Type of motor(iii) Power supply Voltage, Frequency & No. of phases(iv) Output of motor(v) RPM (NO load and full load)(vi) No. of poles and Frame size.(vii) Current Full load and No load.(viii) Starting current (ix) Starting torque
(x) Pull out torque(xi) Run up time(xii) Enclosure & Protection Provided(xiii) Noise & Vibration level(xiv) Class of insulation(xv) Method of starting Remote, local facility & indication(xvi) Type of winding details(xvii) Weight of the motor and starter
45
(xviii) Over all dimensions of the motor and starter .(xix) Terminal connection detail.(xx) Efficiency at 100%, 75% and 50% (xxi) Power Factor at 100%, 75%, 50% load(xxii) Direction of rotation(xxiii) Shaft material(xxiv) Lifting arrangement of motor(xxv) Whether RIS unit provided.(xxvi) Whether heater supply required.(xxvii) Shock grading, method of mounting and requirement of shock mounts.(xxviii) List of onboard and B & D spares
(xix) Rating of the contractors
0807. The documentation for the motor consisting of Handbook/Part Identification lists and drawing should be so prepared that these fulfill the following three basic requirement:
(a) Facilitates repair/rewinding and over hauling of the motor by ship staff/dockyard technicians.
(b) Details of spares which may be required for carrying out onboard repairs/maintenance.
(c) Logistic management so as to enable the store authorities to identify and take procurement action of the spares/equipment.
0808. The documents which are required to be provided by the manufacturers are grouped as follows:
(a) Winding and performance data sheet
(b) Sectional assembly drawing
(c) Part identification list
(d) Dimension sheet.
0809. Winding And Performance Data Sheet This should cover complete and sufficient data to effect rewinding of the motor. The following information should be filled in accordance with table 1 of this section:
(a) Performance
(i) Type
(ii) Frame size
(iii) Power supply
46
(iv) Out put
(v) Poles
(vi) R.P.M
(vii) Full load current
(viii) Efficiency at 100%, 75% and 50% load
(ix) Power factor at 100%, 75% and 50%.
(x) Starting current
(xi) Starting torque
(xii) Pull out torque
(xiii) Temperature rise
(xiv) No load current
(xv) Air gap
(xvi) Safe stalled time
(xvii) Motor weight
(xviii) Details of bearings like, Type, Number, make etc.
(b) Stator Winding Data
(i) Type of winding
(ii) No. of slots
(iii) No. of coil
(iv) Coil pitch
(v) Conductors per slot
(vi) Turns/coil
(vii) Wire gauge
(viii) Weight of winding wire
47
(ix) Winding resistance/phase
(x) Mean length of turn
(xi) Insulation
(xii) Complete details on PTCTs
(c) Winding Data For Coils
(i) Coil former dimension
(ii) Winding diagram
(iii) Type of connection
0810. Sectional Assembly Drawing This drawing should show two or more main views, sectioned as necessary giving the details given below. Each component should be marked with an item number which will conform to the part identification list as per table 2 (clause 6.2.3) of this section:
(a) Main constructional details
(b) Principal dimensions – Detailed dimensions should be indicated in the dimensions sheet as described in clause 6.2.4 of this section.
(c) Details of bearing assembly
(d) Mechanical arrangement of fields or rotors
(e) Fan Assembly
(f) Methods of attachment of fan, cores, bearings etc to the shaft.
(g) A section through the shaft at each key way.
(h) Terminal box and glands
(j) Heater
0811. The main view drawing shall to titled with the order number and date, the name of the organisation for which motor was intended, the service, the type of the motor, the scale and reference to third angle projection.
0812. Part Identification List Part identification list as per the proforma at table 2 of this section should be provided.
48
0813. Dimension Sheet Dimension Sheet for all motors are to be given as per the program at table 3 of this section. This should include shaft and key details along with tolerances. The letter symbols for the typical dimension sketches shown in table 3 of this section conform to IS 1231/IEC 600722, and are as indicated below :
A Distance between centerlines of mounting holes (end view).
AA Width of end of foot (end view)
AB Overall dimension across feet (end view)
AC Diameter of motor
AD Distance from center line of motor to extreme outside of terminal box or other most salient object mounted on side of motor.
B Distance between center line of fixing holes (side view)
BA – Length of foot (side view)
C Distance from shoulder on second shaft to center line of mounting Holes in nearest feet.
CA – Distance from shoulder on second shaft to center line of mounting holes in the nearest feet.
D Diameter of shaft extension.
DA – Diameter of second shaft extension.
E Length of shaft extension from the shoulder
EA – Length of second shaft extension from the shoulder
F Width of key.
FA – Width of key way of the second shaft extension.
G Distance from the bottom of key way to the opposite surface of the shaft extension.
GA – Distance from the top of the key to the opposite surface of the shaft extension.
GB Distance from the bottom of the key way to the opposite surface of the second shaft extension.
49
GC – Distance from the top of key to the opposite surface of the second extension.
GE Thickness of key
GH Depth of key way at the crown of the second shaft extension.
H Distance from centerline of shaft to bottom of feet (basic dimension)
HA Thickness of feet
HC – Top of horizontal motor to bottom feet
HD – Top of eyebolt, terminal box or other most salient object mounted on top of the motor to bottom of feet.
K – Diameter of holes for width of slots in the feet of the motor.
L Overall length of the motor with single shaft extension.
LO – Overall length of the motor when there is second shaft extension.
The documents stated at clause 6.2 and maintenance routines of the motor are to be compiled in a book form before submission.
0814. Binding Drawings. Following binding drawings are to be submitted for IHQ MoD(N) approval.
(i) Overall dimension of the equipment(ii) Mounting arrangement(iii) CG of the equipment
0815. One set of binding drawings is also to be supplied to the shipyard for their comments while forwarding to DQA (WP)/ IHQ MoD(N) at the time of approval.
0816. The manufacturer should furnish the following details for control gear (starter) at the time of tendering:
(i) Service(ii) Type of motor(iii) Voltage, frequency and No of phases.(iv) Protection provided(v) Enclosure(vi) Vibration(vii) Method of mounting and requirement of shock and vibration mounts.(viii) Method of starting, remote and local control facilities and indication
provided.(ix) Weight and overall dimensions of the equipment.
50
(x) List of onboard and B&D spares.(xi) Rating of the contractors
TABLE 1
WINDING AND PERFORMANCE DATA
Manufacturer’s Name
Motor type no./reference no.
Stator winding reference no.
Rotor reference no.
STATOR WINDING DATA
REWINDINGDATA FOR COILS
PERFORMANCE
Type of Winding Connection diagram of winding should be shown in this spaceNo of Slots
No of CoilsCoil PitchConductors per slotTurns per coil Coil former Wire GaugeWeight of Winding WireMean Length of TurnWinding Distance/PhaseInsulation (Class)Slot LinerInter Coil SeparatorsInter Phase SeparatorSleevings
51
TABLE 2
PART IDENTIFICATION LIST
Space for User
Motor type no./reference no.
Manufacture’s name
Serial no.
Drawing no. 0f the sectional assembly drawing.
Item no.
Illustration ref
Makers drg number
Makers part no ref
Naval code no
Description
Material & governing spec
Deno Nos fitted
Remarks
52
SECTION IX
SPARES AND PRODUCT SUPPORT
Onboard And Base & Depot Spares
0901. On Baord Spares. As per section 7 of EEDQ071(R4) one set of onboard spares sufficient for on board maintenance routines/repairs/defect rectification etc for a period of two years to be recommended by the supplier for approval of IHQ MoD(N). A set of approved On Board spares shall be supplied along with the main equipment. Equipment PIL indicating itemwise cost is to be supplied along with the list of onboard spares while obtaining NSM approval.
53
0902. Base & Depot Spares. The quotation for 5 years Base & Depot spares indicating makers part number, cost of each item are to be provided. The quotation for Base & Depot spares should specify a clear validity of 90 days. These are 5 years spares consisting of
(a) Stock quantities of on board spares
(b) Spare parts estimated as requirement for over haul and maintenance tasks to be under taken in Dockyard and base repair organisation.
(c) Important sub assemblies expected to be required for occasional replacement during overhauls for repairs during break downs/damage etc.
0903. Each spare part is to be identified with an unique part number, and are to be priced individually.
0904. Ball and roller bearings used for testing spare rotors are not to be supplied for Naval service.
0905. All spare parts are to be subjected to the same testing, as if being incorporated in a complete motor.
0906. The items listed below are put forward for the guidance of the manufacturers in recommending suitable lists of spares for three phase squirrel cage induction motors/slip ring motors.
Sl. No. Description Onboard spares Base and depot spares
(a) Rotor complete Yes
(b) Stator complete Yes (After scaling Yes done by IHQ based on population and application)
(c) Slip ring Yes
(d) Fan Yes
(e) Set of brush holders Yes
(f) Set of brush spring Yes
(g) Set of bearing Yes Yes
(h) Set of bearing Yes Yes Location spring
(j) Set of oil seal Yes Yes
54
(k) Stator coils Yes Yes
0907. The quotation for Base and Depot spares should specify a clear validity of 90 day, in addition to the information at clause 7.1.3.
0908. Guarantee. The complete equipment shall be guaranteed against all manufacturing defects for the period of 12 months from the date of commissioning of the ship.
APPENDIX ‘A’
‘X’ FORM MANDATORY DESIGN REQUIREMENTS FOR MOTORS
The ‘X’ form is to include the following information:55
The information Ø to be inserted by the ship section.* is to be supplied by the manufacturer of the driven equipment
† is to be as stated by the Statement of Technical Requirementsa. Service
Ø b. Number per ship.
Ø c. Situation on ship.
* d. Output power and speed(s) required.
* e. Duty cycle and number of starts/unit time.
* f. Method of speed Change.
Ø g. Supply details.
* h. Starting torque required.
* j. Maximum starting current
Ø k. Thermocouples to be fitted for type testing (for hot spot sensing) YES/NO.
Ø l. Heaters 230V/115V, 50/60 Hz, 1Ph to be fitted YES/NO.
† m. Enclosure and cooling system.
† n. Degree of submersion.
* o. Mounting arrangements in accordance with IS 1231:1974 & IS 2223:1983.
* p. Particulars of shaft end.
Ø q. Shock grading.
† r. Structural vibration level group reference.
† s. Airborne noise level.
t. Spare gear in accordance with NES 54.
u. Control gear maker. Tender action proposed.
v. Axial and radial loads transmitted to the motor by driven equipment.
† w. Whether grease relief required.56
* x. Direction of rotation on drive end required.
Ø y. Cables and gland sizes.
† z. Minimum bearing life.
57
APPENDIX ‘B’
Commercial Motors – Main Characteristics
Sizes and Ratings
Rated Output KW Frame Size BS 4999
1500 rpm 3000 rpm0.75 2.2 801.5 4.0 90L4.0 4.0 112M7.5 132M11 15 160M22 15 160m30 200L
1. The above ratings apply for ambient temperatures of 550 C. For 700 C ambient derate by 25% . Machines other than this are not to be used without full investigation and type tests. A consequence of the use of these motors is that the design and performance is predetermined and is not amenable to change to suit special uses. The Design Authority is to ensure that the Main Contractor is satisfied that the motor selected is suitable in all respects for the application and this is to be confirmed during equipment type tests.
Mounting Arrangements.
2. Motors are suitable for foot and/or flange mounting with fixing dimensions in accordance with IS 1231 and IS 2223.
Enclosures
3. Totally enclosed, external fan cooled. Degree of protection IP 55 to IS 4691.
Shaft Extension
4. Dimensions of the shaft end complete with tapped hole and keyway.
Bearing
5. B10 Bearing Life 1200 hours
Starting Current
6. Starting current is to be in accordance with Clause 0533 of this specification is to be checked.
58
Starting (Breakaway) Torque
7. The starting (breakaway)torque is not less than 1.4 times full load torque at minimum voltage with minimum torque during the starting period of 0.7 times full load torque.
Shock
8. The shock capability is :
40g vertical, 20g axial and 20 g transverse.
When solidly mounted, foot or flange mounted, the shock resistance is just below Grade D (revised). That is first damage will occur on some motors of a batch at about 30g.
59
APPENDIX ‘C’
Shock Curve NSS GradeI
60
APPENDIX ‘D’
Shock Curve NSS Grade –II
61
APPENDIX ‘E’
Standardised Range of Motors
62
Output Ratings and Frame Size Numbers Chart
Sl. N0. Ratingin KW
2 Poles 50 Hz(3000 rpm)60 Hz(3600 rpm)
4 Poles 50 Hz(1500 rpm)60 Hz(1800 rpm)
6 Poles 50 Hz(1000 rpm)60 Hz(1200 rpm)
8 Poles 50 Hz(750 rpm)60 Hz(900 rpm)
1. 0.18 63 63 71 90 S2. 0.37 71 71 80 90 S3. 0.55 71 80 80 90 L4. 0.75 80 80 90 S 100 L5. 1.1 80 90 S 90 L 100 L6. 1.5 90 S 90 L 100 L 112 M7. 2.2 90 L 100 L 112 M 132 S8. 3.7 100 L 112 M 132 S 160 M9. 5.5 132 S 132 S 132 M 160 M10. 7.5 132 S 132 M 160 M 160 L11. 11 160 M 160 M 160 L 180 L12. 15 160 M 160 L 180 L 200 L13. 18.5 160 L 180 M 200 L 225 S14. 22 180 M 180 L 200 L 225 M15. 30 200 L 200 L 225 M 250 M16. 37 200 L 225 S 250 M 280 S17. 45 225 M 225 M 280 S 280 M18. 55 250 M 250 M 280 M 315 S19. 75 280 S 280 S 315 S 315 M20. 90 280 M 280 M 315 M 315 L21. 110 315 S 315 S 315 M 315 L22. 132 315M 315M 315 L 315 L23. 185 315 L 315 L 355L 315 M24. 200 315 L 315 L 355L 315 L25. 250 355 L 355 L 355 LX 400L26 315 355 L 355 L 400L 400L27. 350 400L 400L 400 450L
63
APPENDIX ‘F’
Power Supply Characteristics of Ships Main A.C Supply
Sl No Parameter Tolerance Levels
1 Voltage Nominal Voltage (a) Load Range Tolerance
(i) Average Line to Line Value of 3PHASE System
(ii) Line To Line Voltage Of Single Phase of 3 Phase System
(b) Maximum Unbalance (c) Maximum Modulation
(d) Transients (Excluding Spikes)(Average Line To Line Value For 3phase system)
(i) “Frequent” Transient High limit Low limit Recovery (ii) “Infrequent ” Transient High limit Low limit Recovery
415V
+ 5%
+ 6%
2%2%
+ 6%10%0.5 sec
+ 10%16%1 sec
2 Waveform (a) Maximum Individual Harmonic (b) Maximum Total Harmonic Content
3%5%
3 Frequency (a) Nominal Frequency (b) Load Range Tolerance (c) Constant Load Tolerance (d) Modulation
(e) Infrequent” Transients High Limit Low Limit Recovery
50 Hz+ 2.5%+0.5%0.25%
+3.75% 3.75% 2 Sec
64
APPENDIX‘G’
Standardised Range 0f Starters And Motors for Various Services
Sl. No. Name Service Type of Starter to be used
1. Motors for general ventilation DOL with provision to Auto below 15KW rating Start when power supply is
restored . Protection at clause0614 of this EEQQ071(R3)
2. Motors for Pumps below 15KW DOL with Protection at clause0614 of this EEQQ071(R3)
3. Motors for General ventilation Star/Delta or Star/Double Star below 15KW with protection at clause
0614 of this EEQQ071(R3)
4. Motors for Air condition and Soft starters with centralized refrigeration motorvision
5. Motors for Fire Main Pump do
6. Motors for HP/LP Air Soft StarterCompressor FL Pumps and pumps above 15KW
7. Motors for Engine Room/ Star/Double star withBoiler Room ventilation centralized motorvision`
8. Steering Motors Soft Starter with protection at clause 0614 with a provision to by pass in case of emergency.
9. Capstan/Winches Bi directional controllers Star/Double Star,/Delta/ Double Star,Double Star / Delta with
protections at clause 0614.
10. Rotary Converters, Soft Starter with protection at Stablisers etc. clause 0614
65
Appendix‘H’
TESTS REQUIRED ON AC MOTORS AND THEIR CONTROL GEARS
The requirement of various tests and their abbreviations used in this table are T Type Test, R Routine Test, L – Test at electrical Maker’s work/Labs and C – Combined Equipment Test
TEST AC MOTORS CONTROL GEARS (STARTERS)
Type Test
Routine Test Type Test Routine Test
L C L C L C L CThermistor Resistance _/ _/ Insulation Resistance _/ _/ _/ _/ _/ _/ _/ _/Winding Resistance (cold)
_/ _/ _/
Earth bonding _/ _/ _/ _/ _/ _/Thermistors resistance (cold)
_/ _/ _/ _/
Measurement of Air Gap _/ _/ Direction of Rotation _/ _/ Over Speed _/ _/ Temperature Rise _/ _/ _/Hot Spot Sensing _/ Winding Resistance (Hot)
_/ _/ _/
Withstand voltage _/ _/Insulation Resistance(Hot)
_/ _/ _/ _/
Thermistors Resistance (Hot)
_/ _/ _/ _/
Dry and Damp heat _/ _/ No load current, power factor and speed (Hot)
_/ _/
Self generated noise and vibration
_/ _/ _/ _/
Speed regulation _/ _/ _/ Starting current and run up time
_/ _/
Efficiency _/
66
TEST AC MOTORS CONTROL GEARS (STARTERS)
Type Test
Routine Test Type Test Routine Test
Locked rotor torque _/ Pull out torque _/ Protection under stall condition
_/
Application of water jet/spray for enclosure upto IP 56
_/ _/ Effectiveness of Enclosure
Immersion for IP 57 _/ IP 58 Submersible motor Immersion/Dynamic Test
_/ _/
EMC _/ _/ Bearing grease relief _/ External Magnetic Field _/ _/ Shock and vibration _/ _/ _/ Conformity with drawings_/ _/ _/ _/ _/ _/ _/ _/Millivolt Drop _/ _/ _/ _/Functional Tests _/ _/ _/ _/ _/ _/ _/ _/Operation of protective devices
_/ _/ _/ _/
67
Appendix ‘J’
Chart on Type 2 Coordination for Starters
Type 2 Coordination chart for DOL & Soft Starter 415V, 3P, 50KA, SCPD Fuse
KW Rating
HP Rating
Line Current
Fuse Rating
Contactor Rating
0.12 0.16 0.51 2 180.18 0.25 0.6 2 180.25 0.33 0.8 2 180.37 0.5 1.2 4 180.55 0.75 1.5 4 180.75 1 2 6 181.1 1.5 2.7 8 181.3 1.75 3 8 181.5 2 3.5 103 182.2 3 4.92 16 18
3 4 6 16 183.7 5 7.5 20 18
4 5.5 8.5 20 185.5 7.5 11 32 257.5 10 14.5 40 259.3 12.5 17.3 50 2511 15 21 63 2513 17.5 24 63 2515 20 29 63 40
18.5 25 35 80 4022 30 40 80 4530 40 54 100 7037 50 68 125 80
68
45 60 81 125 9555 75 94 160 9575 100 130 200 14080 110 139 200 14090 120 157 250 185
110 150 189 250 225
Appendix ‘J’Contd
Type 2 Coordination chart for DOL & Soft Starter 415V, 3P, 50KA, SCPD MCCB
KW Rating
HP Rating
Line Current
MCCB Rating
Contactor Rating
0.12 0.16 0.51 0.63 180.18 0.25 0.6 1 180.25 0.33 0.8 1 180.37 0.5 1.2 1.6 180.55 0.75 1.5 2.5 180.75 1 2 2.5 18
1.1 1.5 2.7 4 181.3 1.75 3 4 181.5 2 3.5 5 182.2 3 4.92 6.3 18
3 4 6 7.5 183.7 5 7.5 10 18
4 5.5 8.5 12 325.5 7.5 11 16 807.5 10 14.5 25 809.3 12.5 17.3 25 8011 15 21 30 8013 17.5 24 35 8015 20 29 50 80
18.5 25 35 50 8022 30 40 60 95
69
30 40 54 80 9537 50 68 100 11045 60 81 120 14055 75 94 160 18575 100 130 200 22580 110 139 200 22590 120 157 230 265
110 150 189 275 325
Appendix ‘J’Contd
Type 2 Coordination chart for StarDelta Starter 415V, 3P, 50KA, SCPD Fuse
KW Rating
HP Rating
Line Current
Fuse Rating
Contactor Rating
5.5 7.5 11 16 187.5 10 14.5 20 189.3 12.5 17.3 32 1811 15 21 32 1813 17.5 24 32 1815 20 29 40 25
18.5 25 35 50 2522 30 40 63 2530 40 54 63 3237 50 68 80 45
Type 2 Coordination chart for StarDelta Starter 415V, 3P, 50KA, SCPD MCCB
KW Rating
HP Rating
Line Current
MCCB Rating
Contactor Rating
5.5 7.5 11 16 807.5 10 14.5 25 809.3 12.5 17.3 30 8011 15 21 35 80
70
13 17.5 24 50 8015 20 29 50 80
18.5 25 35 60 8022 30 40 70 8030 40 54 100 8037 50 68 120 95
71