Revision
Indication
STANDARD SPECIFICATION
uop
UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
VARIABLE SPEED DRIVE SYSTEM
> 1000 HP
1.
5-28-0
Page 1
of
5
DATE
STATUS
APVD
AUTHD
03MAY04
NEW
MRV
RGP
GENERAL
1.1
1.2
Scope
a.
This Standard Specification provides the minimum basic requirements for a
medium voltage (2400 volts and above) AC variable speed drive system (VSD)
for three phase squirrel cage induction motors, 1000 horsepower and larger.
b.
Exceptions or variations shown in the UOP Project Specifications take
precedence over requirements shown herein.
References
Unless noted below, use the edition and addend of each referenced document current on
the date of this Standard Specification. When a referenced document incorporates
another document, use the edition of that document required by the referenced document.
2.
a.
American Petroleum Institute (API) Standard 541, “Form-Wound Squirrel Cage
Induction Motors - 250 Horsepower and Larger”
b.
API Standard 617, “Axial and Centrifugal Compressors and ExpanderCompressors for Petroleum, Chemical and Gas Industry Services
c.
Institute of Electrical and Electronic Engineers (IEEE) 112 “Standard Test
Procedure for Polyphase Induction Motors and Generators”
d.
IEEE 519 “Guide for Harmonic Control and Reactive Compensation of Static
Power Converters.”
e.
National, state, and local governmental regulations and laws
DRIVE SYSTEM
2.1
The VSD system shall be designed to operate the Owner’s centrifugal compressor at
speeds ranging from a maximum of rated RPM down to a minimum value determined by
drive system vendor, but not less than minimum speed requirement of the driven
equipment. The minimum value shall be as low as possible without requiring special
motor cooling or bearing lubrication arrangements.
2.2
The VSD system shall provide a soft-start torque profile for the motor and shall provide
for smooth, step-less acceleration/deceleration over the entire operating speed range.
2.3
Critical speeds of all drive train components and required separation margins per API
Standard 617 shall be taken into consideration.
Form QUA-03-3
Revision
Indication
STANDARD SPECIFICATION
uop
UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
VARIABLE SPEED DRIVE SYSTEM
> 1000 HP
5-28-0
Page 2
of
5
DATE
STATUS
APVD
AUTHD
03MAY04
NEW
MRV
RGP
2.4
The VSD shall have air break contactors rated for motor duty and suitable for motor
protection and isolation. The contactors shall be electrically operated and suitable for
interfacing with the plant control system.
2.5
The drive system provided shall be a complete turnkey package installation with the
following basic equipment and features:
a.
b.
c.
d.
e.
f.
g.
h.
Liquid or air cooling
Input AC line reactor or isolation transformer
AC-DC converter
DC link reactor/filter
Heat exchanger for cooling drive system
Load converter for changing DC to adjustable frequency AC for controlling
motor speed.
Control module
Contactor/switchgear module
2.6
Total harmonic distortion of motor volts and amps shall be less than 5% at full speed
(when load is a maximum). Motor volts and amps shall contain no transients.
2.7
A by-pass system shall be designed to provide a smooth, closed transition synchronous
transfer of the induction motor from the drive to the main AC line and from the AC line
back to the drive. Transition shall be accomplished without stopping or slowing down
the motor and without any significant transients on the line.
2.8
An input line isolation device shall be provided between the medium voltage bus and the
drive. The isolation device shall be a line reactor or an isolation transformer and shall
meet the requirements of IEEE Standard 519.
2.9
A line reactor may be utilized provided the motor insulation is one class of insulation
higher than the operating voltage (e.g., 4000 volt system with 7.5 KV insulated motor.)
2.10
An isolation transformer shall be dry type, self cooled, 220°F (105°C) rise with Class H
insulation for installation outdoors. Transformer shall be rated for rectifier duty and
suitable for switching currents. Transformer shall allow full voltage starting in the case
of VSD bypass. Transformer primary winding shall have 2 ½ percent taps above and
below normal voltage.
2.11
A thyristor bridge cubicle shall be provided for the inverter and converter and shall
consist of power switching thyristors mounted in phase cells. Each phase cell shall
contain redundant thyristors in series to allow system operation to continue in the event of
a device failure. A heat sink cooling system with a remote heat exchanger shall be
provided for the VSD to insure low heat loss in the electrical control room.
2.12
The drive manufacturer shall quote, as an option, a completely withdrawable fused
contactor to by-pass and isolate the drive for VSD maintenance or to operate the motor at
full speed. The contactor shall include a Mullion 169+ overload protector relay.
Form QUA-03-3
Revision
Indication
STANDARD SPECIFICATION
uop
UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
VARIABLE SPEED DRIVE SYSTEM
> 1000 HP
3.
5-28-0
Page 3
of
5
DATE
STATUS
APVD
AUTHD
03MAY04
NEW
MRV
RGP
CONTROL PANEL AND CONTROL MODULE
3.1
Indicators, controls, ammeters, voltmeter and frequency meter shall be visible on a swing
out panel on the front of the control module.
3.2
The control module shall contain all the modules necessary to monitor, analyze, control
and protect the system, and shall be suitable for remote communication and display. The
software based monitoring system shall not control system operation or shutdown.
System control, protection and regulation shall be completely hardware based for
reliability.
3.3
The control module shall receive a 4-20 milliamp control signal and shall adjust the speed
directly from that signal. This module shall contain all of the start-stop and frequency
control logic specified.
3.4
The control module shall contain the regulators necessary to maintain the following
parameters at the desired set point or within preset limits:
a.
b.
c.
d.
3.5
Drive system malfunctions resulting in a shut down shall include, but not be limited to:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
3.6
Stator overvoltage
Rectifier overcurrent
Stator overcurrent
Inverter overcurrent
Control logic failure
Power supply undervoltage
Loss of blower cooling
Open phase
Multiple thyristor failure
Ground fault
Overspeed
Instantaneous overcurrent
Bearing high-high temperature
Excessive vibration
The control module shall continuously process the monitored data and, as a minimum,
provide fault alarm indication in the form of light emitting diodes for:
a.
b.
c.
d.
e.
f.
g.
h.
Form QUA-03-3
Output frequency or motor speed
Input amps and output amps
Output volts and output volts/hertz ratio
Acceleration rate, deceleration rate
Stall condition
Command loss
Output AC phase to ground faults
DC ground faults
Motor phase unbalance.
Cooling failure (pump, fan, liquid level or temperature, etc. as required)
Varistor failure (with definition of the actual device)
VSD high temperature
Revision
Indication
STANDARD SPECIFICATION
uop
UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
VARIABLE SPEED DRIVE SYSTEM
> 1000 HP
4.
5-28-0
Page 4
of
5
DATE
STATUS
APVD
AUTHD
03MAY04
NEW
MRV
RGP
DC LINK REACTOR/FILTER
Two direct current links shall be provided (one for the positive, one for the negative DC side of
the power bridges) as a filter to protect the motor from line voltage disturbances. The reactors
shall be dry type, air core, convection cooled, with Class F insulation not to exceed Class B
temperature rise.
5.
VSD INTERFACING
5.1
VSD Output Interfacing
Following are the minimum outputs required for VSD interfacing with the main control
board:
a.
b.
c.
d.
e.
f.
VSD in the automatic mode
VSD ready for startup
VSD output speed (4-20 mA)
VSD output kilowatts (4-20 mA)
Each alarm function
Each trip function
Provide also a speed indicator local to the motor
5.2
VSD Input Interfacing
a.
Following are the minimum inputs required for VSD interfacing with the main
control board. Form C contacts are to be provided for each input.
(1) Start (normally open)
(2) Stop (normally closed)
(3) Input signal (4-20 mA frequency command)
(4) Switchgear contactor auxiliary contact (open with contactor open)
b.
Provide diagnostic and communication functions integral to the standard control
module as follows:
(1) On-board monitoring and fault analysis
(2) Memory for data acquisition
(3) Modem for remote two-way communication and display of all optional
diagnostic and protection features offered.
6.
INDUCTION MOTOR
The form wound squirrel cage motor shall be in strict compliance with the electrical and
mechanical requirements of API Standard 541 and the Purchaser’s Motor Data Sheets.
Form QUA-03-3
Revision
Indication
STANDARD SPECIFICATION
uop
UOP LLC • 25 East Algonquin Road • Des Plaines, Illinois 60017-5017 • USA
VARIABLE SPEED DRIVE SYSTEM
> 1000 HP
7.
8.
5-28-0
Page 5
of
5
DATE
STATUS
APVD
AUTHD
03MAY04
NEW
MRV
RGP
ADDITIONAL REQUIREMENTS
7.1
Audible noise generated by the controller under any condition of operation shall not
exceed a sound pressure level of 65 dBA measured five feet (1.5 M) from any surface of
the enclosure.
7.2
The drive manufacturer shall provide a computerized torsional resonance analysis and an
electrical harmonic analysis. Potentially harmful harmonics and torque shall be evaluated
and preventative measures implemented.
7.3
The VSD manufacturer shall have a minimum of 10 variable speed drive installations
operating at least 3 years of the type quoted for the same voltage and similar horsepower.
7.4
Spare parts recommendation for the drive system shall be furnished by the supplier.
7.5
A training course at the refinery for personnel associated with the operation, maintenance,
or repair of the system shall be proposed by the drive system supplier.
TESTING
8.1
All components shall be 100% tested.
8.2
Testing (burn-in) of individual components shall be provided by the drive manufacturer.
System efficiency to be determined by segregated losses of the individual components in
accordance with IEEE 112, Method E or F.
8.3
Every thyristor shall have the following critical parameters tested at rated current:
a.
b.
c.
d.
e.
Gating
Turn-on, turn-off
High temperature
Forward blocking, reverse blocking
Waveform characteristics.
8.4
All assembled phase cells shall be tested for cell balance at rated voltage, maximum
current, maximum dV/dT and maximum dI/dT.
8.5
The complete drive shall be burned-in at full load amps for a continuous 24 hours.
8.6
Control power shall be applied to microprocessors (when applicable), printed circuit
boards, diagnostic boards and similar devices, including software to test for proper
sequencing, logic and diagnostics.
Form QUA-03-3