API 541 5th Edition Understanding The Changes And .
API 541 5th Edition – Understanding the Changes andUpdates to one of the Petroleum Industry’s PremierSpecificationsBart Sauer - Siemens Industry, Inc. Norwood Motor PlantMark Chisholm – Siemens Industry, Inc.
Petroleum Industry Motor Standards500 kVA 500kVASynchronous machinesAPI 546 3rd‘Custom’API 541 5th2 pole WPII2 pole TEFC‘Standard’ 500HPAPI 547 1stVertical250 – 3000HP 4/6/8p“Non-critical”IEEE 841 2009 500HP, 4kV, TEFCH & V, A/F brgsHP 1kWSauer May 2017250185500375800 1250600 9303000224010000Now metric100000Page 2
American Petroleum Institute – 541 History RP 541 introduced in 1972 541 2nd Edition introduced in 1987 541 3rd Edition introduced in 1995 541 4th Edition released June 2004 541 5th Edition – Released December 2014 End User Driven Specification, with representation by MotorSuppliers.Sauer May 2017Page 3
API 541 5th - Timing / Process of Revision Working group assembled April 2008 End users, Consultants . . . and motor OEMs Open discussions on suggested improvements Incorporate API 546 revisions as appropriate Sub-groups to discuss/recommend broader changes Ballot (second) approval May 2011 Print proof reviewed in July 2012 Published December 2014Sauer May 2017Page 4
Why Use API 541? Standard specification that provides customized product Creates motor definitionDictates proposal preparationSimplifies proposal evaluationProvides for a reliable machine Utilizes comprehensive data sheets Important to everyone involved from manufacturer to userSauer May 2017Page 5
API 541 5th Edition - ScopeThis standard covers the minimum requirements for special purpose form-wound squirrel-cage induction motors 375kW (500 Horsepower) and larger for use in petroleum, chemical and other industry applications.Note 1: Special purpose machines typically have one or more of the following characteristics:1. Is in an application for which the equipment is designed for uninterrupted, continuous operation in critical service,and for which there is usually no installed spare equipment.2. Is larger than 2250 kW (3000 hp) for speeds 1800 RPM and below.3. Is rated 600 kW (800 hp) or greater for two-pole (3000 or 3600-RPM) machines of totally-enclosed construction, orrated 930 kW (1250 hp) or greater for two-pole machines of open or guarded construction (including machines withWP-I or WP-II type enclosures).4. Drives a high-inertia load (in excess of the load WK2 listed in NEMA MG 1 Part 20).5. Uses an adjustable speed drive as a source of power.6. Is an induction generator.7. Is a vertical machine rated 375 kW (500 hp) or greater.8. Operates in abnormally hostile environments.Sauer May 2017Page 6
Baseline .API 541 4th Edition –Standard Motor Features – Basic Design Class B temperature rise at 1.0 SF by RTD (2.3.1)Method ofHPVoltage DeterminationHP V RESistanceHP 1500 V DETectorHP 1500 V 7000 DETectorHP 1500 V 7000 DETectorA60706560ClassBF80 105901158511080105H125140135125 Maximum sound pressure level 85 dB(A) @ 3 feet (2.1.3) Suitable for 80% voltage starting Special starting duty: 2 Hot / 3 Cold Starts, Minimum Safe Stall Time criteria: the greater of 150%, or 5 sec morethan acceleration time. Inrush current 650% of full-load current C-5 stator lamination core plate Both ends of each stator-phase winding brought out to main box (1000 hp & )Sauer May 2017Page 7
Baseline .API 541 4th Edition –Standard Motor Features – Basic Design Metal fan-coversWPII - stainless steel filters & provisions for differential pressure switchStainless steel hardware (up to ½“)Specific mounting surface dimension tolerances Heat-treated forged shafts (A4000 Series) for: Motors with finished shaft diameter 8 inches2-pole motors 1000 hpMotor operating above first critical speedReciprocating loads and motors using tapered hydraulic-fit couplingsSauer May 2017Page 8
API 541 4th Edition –Standard Motor Features Specific TEWAC and Vertical Motor design criteria. Split-sleeve, ring-oil lubricated bearings (horizontal units) Bearing temperatures not to exceed 93ºC at rated output Provisions for shaft displacement probes (motors operating 1200 rpm) Both bearings insulated 3-Wire, 100 Ohm Stator RTD’s (2/Phase) Flanged Forced/Flood Lube Provisions (when applicable) Shaft material certificate Foundation loading data on GA drawingSleeve Bearing w/ InsulationSauer May 2017Page 9
API 541 4th Edition –Standard Motor Features Copper rotors (Aluminum allowable if approved by purchaser) with Phosphorous-free braze material(Cu bar rotors) Special rotor balance procedures (Step Balance 2 & 4-poles) 1.5 mils (0.0015”) p-p shaft displacement vibration limit (unfiltered) 0.1 IPS (inches/sec) vibration limit on bearing housing 0.6 mil (max), cold-to-hot magnitude resultant vector change (1x) vibration criteria (4.3.3.11).Sauer May 2017Page 10
Aluminum Die Cast Rotors ShaftLaminated steel coreRotor bars/short circuit ringsAir ductInternal fanExternal fanSauer May 2017Page 11
Copper Bar Rotor ShaftLaminated steel coreCopper rotor barsCopper short circuit ringsHigh tensile retaining ringsInternal fansSauer May 2017Page 12
API 541 4th Edition – Form-wound Squirrel Cage Induction Motors Routine Testing Coil Surge comparison testsSoft-foot check must be made prior to any mechanical running testHigh-potential testPolarization indexNo-load bearing run bearing temperature riseBearing inspection (sleeve bearings)Vibration testSauer May 2017Page 13
API 541 5th - Notable Changes Service life and Service FactorInsulation temperature limitsEnclosuresAccessoriesShaft forgingsThermal capacity dataMagnetic stator slot wedgesMain terminal box featuresSauer May 2017 ASD design requirements Testing Data sheet & guidePage 14
RevisedAPI 541 5TH Edition – Basic Design Minimum service life / years of un-interruptedoperation now required to be 25 / 5 years Was 20 / 3 years (4.1.1) Machines shall have a 1.0 service factor Stronger, clear wording (1.15 SF undesirable) (4.2.1.4)Must address temperature rise if customer requires 1.15 SF. If overload capacity is required, a higher nominal motor rating shall be selected Avoids operating motors above rated power, which increases winding temperatures and shortens motor life
RevisedAPI 541 5TH Edition – Insulation Temperature Limits Meet class B temperature rise by resistance AND byRTD (4.3.1.1.b).MethodofHPVoltage DeterminationHP V RESistanceHP 1500 V DETectorHP 1500 V 7000 DETectorHP 1500 V 7000 DETector RTDs measure “hot spot” temperature RTDs inserted between coils in the slots Average temperature determined bychange of winding resistance Permitted hot spot rises are 0 to 10 Cabove average risesA60706560ClassBF80 105901158511080105H125140135125 Occasionally average exceeds hot spotmeaning hot spot is not the worst case Now required to meet the limits by bothmethods Ensures temperature limits are metthroughout windings
NewAPI 541 5TH Edition – Enclosure Changes Totally enclosed motors required at 6kV and up (4.4.1.1.f) For example, TEFC, TEAAC or TEWAC Default requirement TEAAC/CACAFree to specify open enclosure if good experience at siteData sheet field added to give user place to waive this in favor of WP-II Minimizes airborne contaminants Reduced risk of electrical trackingReduced risk of early winding failureTEWAC/CACW TEWAC motors are required to include a flow-sensing deviceand air RTD's (into and out of cooler) now as standard (4.4.1.2.4)
NewAPI 541 5TH Edition – Accessory Changes New auxiliary terminal box design criteria: 316 SS required for Offshore and Marine duty (5.1.4.1)Breather/Drain required (5.1.4.1)Flexible conduit length is not to exceed 0.9 meters (5.1.12)Customer conduit and cable entrances to be in bottom or sides only (5.1.13) Bearing RTD’s are now required as standard on motors with hydrodynamicradial and thrust bearings (5.3.1) 100 Ohm RTD unless otherwise specified on the motor data sheet.
NewAPI 541 5TH Edition – Accessory Changes (3) Stator RTD’s per phase (5.2.1.2) 2 per phase was former standard. Revised Space Heaters Criteria (5.4.1-3) T3 temp code, not to exceed 160̊ C lower(Space heaters remain a “when specified” option).
RevisedAPI 541 5TH Edition – Shaft Changes 4.4.5.1.3 Heat-treated forged steel shafts shall be used for machines having any of the following characteristics:a) finished shaft diameter 200 mm (8 in.) and larger;b) two pole machine;c) operation above the first lateral critical speed;d) driving a reciprocating load; ore) using a tapered hydraulic fit coupling.Hot-rolled shafts may be used for all other machines if the vendor can demonstrate a minimum of two yearssuccessful operating experience with the design in that application.4.4.5.1.4 When specified, the shaft and spider shall be machined from a one-piece heat-treated forging.4.4.5.1.5 Heat-treated forged steel shafts shall be AISI 4000 series and comply with ASTM A668 or equivalent in EN10250. ALL 2 pole motors (4.4.5.1.3.b) Was 1000 hp & larger (4th) All 2-poles (3rd)
RevisedThermal Capacity Data Supplier now required to provide thermal capacity data, including: Thermal limit curves Acceleration curves Required stop/running cool times after max starts Useful for programming motor protection relaysSauer May 2017Page 21
NewMagnetic Stator Slot Wedges (4.3.10) Not previously been addressed Used by many vendors and can improveperformance but some have durability issues Requirements – Rigid and VPI’d in place, amorphous orcomposite construction, 10 year track record,630 mm shaft height limitation Advise use on proposal data sheetSauer May 2017Page 22
NewAPI 541 5TH Edition - Main Terminal Box Features NEMA Type II T-box with bus bar onstandoffs now standard. (5.1.1) Large box - may require supportStandoff insulators shall be either porcelain orcycloaliphatic resin material (not glastic). Optional Surge Capacitors now must bethree separate single phase caps, vs.common ‘three-phase” single assemblysurge cap (5.6.2.1) “3-ph” version shown, is common Default requirement now for fault withstandcapability / rupture disc in main t-box (5.1.2), itwas optional
RevisedAPI 541 5TH Edition – ASD Motor Design Many new requirements and notes throughout the standard created for ASDapplications and for purchaser information/review of application When specified, mutually agreed sound level on ASD (4.1.4)When specified, mutually agreed over-speed capability (4.1.5)Mutually agreed upon voltage and frequency ratings (4.2.1.2.3)Starting & Running, new note for ASD starting (4.2.3.3)Supply from ASD only, starting characteristics can differ from ACL requirements (4.2.4.5) Note: Rotor and Stator temps Note: Torsional oscillations from drive harmonics Note: Damage due to improper applicationPurchaser to advise significant ASD harmonic content (4.3.1.2)Purchaser to advise ASD voltage spikes (4.3.1.2.1)Purchaser to advise ASD common mode voltage (4.3.1.2.2)Mutually agree on strategy to avoid structure resonances (4.4.2.1.1)Well damped rotor natural frequency if within speed range (4.4.6.1.2)Symbol used toidentify paragraphs in541 with ASD relatedcontent
ASD CONDITIONSINDUCTION MOTORAPI 541 5th Edition -- DATA SHEETSU.S. CUSTOMARY UNITSPURCHASER'S SELECTIONSN.A.JOB NO.REQ. / SPEC. NO.REVISION NO.USER2LOCATION3PROJECT NAME4SITE / PLANT5Applicable To:DATEBYREV. DATEBold Italics Indicate Default Selection1ITEM / TAG NO.PURCHASE ORDER NO.1PAGEOF12RevAPPLICATIONmSUPPLIERMotor Power Source: Sine Wave PowermASD Power (complete below section)SUPPLIER REF. No.NUMBER of UNITS REQUIREDm Proposalm Purchase m As Designed m As BuiltMOTOR TAG No.(s)Adjustable Speed Drive (ASD) Conditions, if applicable (4.1.4; 4.1.5; 4.2.1.2.3, 4.3.1.2):Bold Italics Indicate the Standard's Default Selection - Refer to Annex C for Data Sheet GuidanceBASIC DESIGN - Generalmmmm6mApplicable Standards (1.3.2; 2.0): North American (i.e., ANSI, NEMA)ASD only operation (4.2.4.5)m7Power / RPM Ratings are Specified by:8Nameplate Power Rating (4.2.1.1):9Nameplate Voltage/Ph/Hz Rating (4.2.1.2):User/Project10Nameplate Ambient Temp. Rating (4.3.1.1,b):11Stator Insulation Class (4.3.1.1,a):12Stator Temperature Rise (4.3.1.1,b)*: Class B13Duty (4.1.2):40 o CmmmASD DOLStart capabilitymOtherHPkWVoltsmmContinuousMotor Speed:OOther:CmHertzmOther:15Voltage and Frequency Variations (4.2.1.3):16Motor Power Source: Sine Wave PowerPer NEMAmm85 dBARPMOther:dBAOther:mASD Power (complete below section)Solid State Soft Starter - Complete data on page 6, line 8Adjustable Speed Drive (ASD) Conditions, if applicable (4.1.4; 4.1.5; 4.2.1.2.3, 4.3.1.2):Constant Power SpeedRange:mm Max SpeedmASD only operation (4.2.4.5)ASD DOL Start capabilityASD only w-Bypass to Utility PowerRPMm ASD w-DOL Start & Bypass to Utility21mmm22ASD Description and Information affecting motor design (Obtain from ASD Supplier; refer to Data Sheet Guide)20ft-lb* (See underlined sentences in Data Sheet Guide for this item)Other:Max. Sound Pressure Level @ 1 m. @ no load, full voltage/frequency on sine wave power (4.1.3; 4.1.4):19CRPM1418ASD only w-Bypass to Utility PoOMinimum Rated Operating Ambient Temp.(4.1.2):Other Class:Constant Torque Speed Range: Min Speedm17RPM (Synchronous)PhaseVariable Torque Speed Range: MinSpeedmClass FmUse SI (metric) data sheets for International Standards (IEC, etc.)OEMVariable Torque Speed Range: Min SpeedRPMConstant Torque Speed Range: Min SpeedRPMConstant Power Speed Range: Max SpeedRPMft-lbMax. SpeedRPMft-lbMax. SpeedRPMft-lbft-lbASD Description and Information affecting motor design (Obtain from ASD Supplier; refer to Data Sheet G23ASD type / topology:ft-lbASD type / topology:24ASD Output Harmonics, describe and/or attach data (4.3.1.2):25ASD Maximum Voltage Spike Amplitude and Rise-Time at drive output (4.3.1.2.1):26ASD Maximum Common Mode Voltage (CMV) at drive output (4.3.1.2.2):27Other ASD information / motor requirements:Volts@microsecondsVoltsASD Output Harmonics, describe and/or attach data (4.3.1.2):2829Area Classification (4.1.8):mNonclassified30mClassified as:ClassGroupTemperature Code (T-code):or ZoneDivisionAutoignition Temperature (AIT):oCASD Maximum VoltagemSpike Amplitude and Rise-Time at drive output (4.3.1.2.1):313233Other:Site Data (4.1.2; 4.4.8.3; 4.4.10.4):Site Ambient Temperature:Minimum Rated Storage Ambient Temp.(4.1.2):MaxOmMinSite Elevation:CmOFOCft.m at drive output (4.3.1.2.2):ASD Maximum Common ModeVoltage (CMV)mmm mm m34Relative Humidity:35Motor Location:m36% MaxIndoor% MinBuilding Temperature Controlled:Outdoor37m38Unusual Site Conditions, Define:Seismic Loading (4.4.2.2), IBC Zone:Roof Over Motor:Use Higher Elevation for motor rating:NomNoYes Controlled Temp.:mYesImportance Factor:Other ASD information / motor requirements:41mmm42Other:3940mmOFft.OCUse for motor ratingOffshore Platform / similar marine environment (4.4.1.1.c)Other Seismic Requirements:Additional Environment Considerations, Chemicals, etc. (4.1.2):Abrasive Dust Protection, Open Enclosures (4.4.1.2.2,c):Corrosive Agents in Environment, re: stress corrosion cracking (4.4.10.1.2):43Sauer May 2017Page 25
NewAPI 541 5TH Edition – Testing Changes Main T-Box requested to be mounted duringperformance testing (6.3.1.3) New Optional TEWAC Heat ExchangerPerformance Test (6.3.5.5) Test verifies performance during factory load testing Verify flow and temperatures per specification New Optional Overspeed Test (6.3.5.6) Test shall be run for two minutes at the overspeed listedin NEMA MG 1, Part 20; IEC 60034-1; or to the specifiedtrip speed (including overshoot) of the connectedequipment (whichever is greater).
RevisedAPI 541 5TH Edition – Sample Coil Tests (6.3.4.2.1)Optional tests to verify coil integrity and VPI process(Two extra coils VPI’d with stator) Impulse test Ground wall 5 PU, 1.2 µs Turn-to-turn 2.0 & 3.5 PU 0.1 to 0.2 µs Then test to destruction Cut coils (3 segments) and examine Coils that use semi-conductive coating in the slot sectionshall be subjected to a partial discharge test at rated line-toneutral AC voltage.Sauer May 2017Page 27
NewAPI 541 5TH Edition – Stator Partial Discharge Testing (6.3.4.6) New option. 6kV & Higher an off-line partial discharge test shall be performed on the stator windings, in accordance with Clause 10.2of IEEE 1434 or IEC TS 60034-27. Test voltage shall be 120 % of the rated phase-to-neutral voltage, maintained for at least five minutes. The vendor shall provide the purchaser with partial discharge test data of similar machines with the sameinsulation system for comparison. The acceptance criteria shall be mutually agreed upon between thevendor and purchaser prior to performing the tests.
NewAPI 541 5TH Edition – Mount ½ Coupling (6.3.1.5) Vibration check test now required when ½coupling hub is mounted by motormanufacturer
RevisedAPI 541 5TH Edition – Unbalanced Response Test (6.3.5.3) Mass moment simulator included during testing (option before) Vibration levels reduced, e.g. 3600rpm: 2.25 mils from 2.74 mils 1800rpm: 2.25 mils from 3.87 mils First critical speed must match predicted (LCSA) results (within 5%) If not, correct modelSauer May 2017Page 30
Sauer May 2017Page 1Copyright Siemens AG 2009 - All rights reservedNo portion of this document may be reproduced either mechanically or electronically without the prior consent of Siemens.Page 31
API 541 5th EditionData Sheets & GuideSauer May 2017Page 32
RevisedAPI 541 5TH Edition - Data Sheets – Annex A Data Sheets completely redesigned1.1.2This standard requires thePurchaser to specify details and features.The Purchaser shall complete the datasheets in Annex A.
INDUCTION MOTORAPI 541 5th Edition -- DATA SHEETSU.S. CUSTOMARY UNITSPage 4/4 Motor Supplier Order DataAPI 541 5th Edition -- DATA SHEETSINDUCTION MOTORSN.A.12JOB NO.ITEM / TAG NO.INDUCTIONHOW TOMOTORUSE THIS DATA SHEET:PURCHASE ORDER NO.API 541 5th Edition -- DATA SHEETSREQ. / SPEC. NO.U.S. CUSTOMARY UNITSRefer to the Data Sheet Guide for comprehensive guidance on all content within this data sheet, which is greatly revised from theREVISION NO.DATEPURCHASER'S SELECTIONSInstructionsBold Italics Indicate Default SelectionINDUCTION MOTORAPI 541 5th Edition -- DATA SHEETS1PAGEITEM / TAG NO.REV. DATEJOB NO.APPLICATIONPURCHASE ORDER NO.12OFUSERRevThe Supplier / Vendor and / or Manufacturer is responsible for selections, data and revisions on page 8 - PROPOSAL DATA, where2 LOCATIONSUPPLIERREQ. / SPEC. NO.U.S.CUSTOMARY UNITSthe Supplier is to provide details about mmm9mmmmmmmmmmmmmmmlvtmmmm12OFRevITEM / TAG NO.mmmmmmmmmmmmmmmmmm mmmmmmmmm mmmmmmmmmmmmmmmmmmmmmm39404142mmmmmmmm mmmmmmmmlmmmmmmmmmmmm mmmmlmmmmmmmInspection & mmmmmmmmSpecial Tools Included in Proposal (4.1.11, 8.1.13):Machine Proposed is in Strict Compliance with API 541 5th Edition? (8.1.9)m Yesmmmmmmmmmmmmmmmmmmmm mmmmvvm No m List of Applicable Exceptions Attachedmmmmmmmmmmmmmmmmmmmmm44 mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm38 Magnetic Stator Slot Wedges Used (4.3.10): m YesmvNo40Liquid Penetrant TestMomentary(6.2.2.5), Define Parts:vmmmVertical Pumps:lbsMomentarylbsThrust BearingDownthrust39 When Enclosure Pre-Start Purging is specified,Upthrustvendor defined maximum allowable pressure (4.4.1.1, e):Load 41(4.4.7.1.11,a)HydrostaticTest (6.2.2.6),Define Parts:vContinuouslbsContinuousmm v lbsm40 Low Ambient Temperature Precautions (4.4.10.4):42 Certified Data Prior to Shipment (8.6.2, a)Other Information:m v41 Special Winterizing Requirements (8.1.15):43 All Required Test and Inspection Equipment (6.1.4) Provided by SupplierOther:m42 Machine Net Weight (8.1.5):lbs.mmmmmmmm
API 541 5th Edition - Scope This standard covers the minimum requirements for special purpose form-wound squirrel-cage induction motors 375 kW (500 Horsepower) and larger for use in petroleum, chemical and other industry applications. Note 1: Special purpose machines typically have one or more of the following characteristics: 1. Is in an .
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