BY TIM RAHILL & MICHAEL C.

FOUSHA

Separating the scope of petrochemical industry induction motor standards

HE

PETROCHEMICAL

industry utilizes standards in the specification and procurement of ac motors. They

may be developed internally or based on standards developed by industry associations. This article identifies and focuses primarily on the three most commonly used industry standards for induction motors. As there is an overlap in the scope of these three standards, this article explains their separate scopes and offers a guide to selecting and

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applying them to assist those responsible for choosing motor standards.

Standards for Motors in Petrochemical Industry There are many standards in place for the specification and procurement of electric motors. A list of foundation and industry standards in common use is given in Table 1. A foundation standard is the one that establishes the basic dimensional and performance standards for equipment used throughout all industries. Organizations such as the National Electrical Manufacturers Association (NEMA) [2] and the International Electrotechnical Commission (IEC) [3] have created foundation standards. Evolving from these, we find standards developed by industry associations to define more detailed and specific performance requirements
Digital Object Identifier 10.1109/MIAS.2008.930893
STOCKBYTE

14

1077-2618/09/$25.002009 IEEE

above those of the foundation standards. We differentiate an industry standard from a foundation standard. An industry standard is the one that has been developed by standards organizations, such as the IEEE, the American Petroleum Institute (API), and the Process Industry Practices (PIP) group, for use by any organization or company. A company standard is the one developed within an individual company for internal use. These may also be used by engineering companies as the basis for a specific project (project standard). Company or project standards may be based on an industry standard, with additional requirements or decisions relating to specific paragraphs within the industry standard. This

would be an overlay standard. A company standard may also be completely independent of an industry standard, developed separately and standing on its own. A company within the petrochemical industry has the opportunity to select and use one or more of these approaches to standards, some of which were specifically developed for their industry segment and may be adopted by other industry segments. The trio of standards developed for petrochemical industry induction motors continue to evolve, and the casual user may not understand how these industry standards were intended to be applied. These three standards are IEEE 841 [1], API 541 [5], and API 547 [6].

TABLE 1. FOUNDATION AND INDUSTRY STANDARDS IN COMMON USE. Standard NEMA MG 1-2006 CSA 22.2-100 IEC 60034-1 IEC 60072-1 Type Foundation Foundation Foundation Foundation Title Motors and generators Motors and generators Rotating electrical machines, Part 1: Ratings and performance Dimensions and output series for rotating electrical machines, Part 1: Frame numbers 56400 Dimensions and output series for rotating electrical machines, Part 2: Frame numbers 3551,000 Polyphase induction motors for power generating stations IEEE standard for petroleum and chemical industry; severe duty TEFC squirrel cage induction motors: Up to and including 370 kW (500 hp) Form-wound squirrel-cage induction motors: 500 hp and larger General-purpose form-wound squirrel cage induction motors: 250 hp and larger Form-wound squirrel-cage induction motors: 250 hp and larger Alternating current squirrel cage induction motor (600 V and below) specification General-purpose application of API 541 3rd edition: Form-wound squirrel-cage induction motors: 250 hp and larger Special-purpose application of API 541 3rd edition: Form-wound squirrel-cage induction motors: 250 hp and larger Form-wound brushless synchronous motors: 500 kVA and larger Date 2006 2004 2004 1991

IEC 60072-2

Foundation

1990

ANSI C50.492000 IEEE Standard 841-2001

Foundation or industry Industry

2000
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2001

API 541-2003, 4th edition API 547, 1st edition API 541, 3rd edition PIP ELSMT01

Industry Industry

2004 2005

Industry Industry

1995 2004

PIP ELSMT02

Industry

Withdrawn, February 2007

PIP ELSMT03

Industry

Withdrawn, February 2007

API 546

Industry

1997 15

With this background and that of API Standard 541, API Standard 547 has evolved, and it is designed to apply API 547 PROVIDES to 2503,000 hp motors (with some A SIMPLIFIED limits, see the following discussion and Flow Chart for Selecting Motor StanAPPROACH dards). As it is based on API Standard 541, its requirements are equivalent to TO THE the minimum requirements of 541. Contrary to the misperception of some, SPECIFICATION 547 is not 541-lite. In fact, the miniReview of 841, 541, and 547 mum requirements for a 547 motor A comparison of these three standards OF LARGE include preselected features that are norwas presented at the IAS Petroleum and MOTORS FOR mally optional in 541, as the authors of Chemical Industry Committee (PCIC) 547 intended to provide those features in 2004 [7]. It provided a more detailed GENERALnecessary to deliver the reliability of a comparison of these standards than we 541-based general-purpose motor withintend to provide here. For a quick PURPOSE out the need to complete a data sheet. review and comparison, see Table 2. The simplification found in 547 proIEEE Standard 841 is typically used APPLICATIONS. vides users with 541-like quality withfor low-voltage (e.g., 460 V) motors that out the detail-driven data sheets found are 250 hp and below. This is also the in 541. (There is a short, three-page typical limit for motor suppliers offthe-shelf inventory for 841 motors. Although the scope of data sheet that one can use in 547 to define user- or project841 accounts for low- or medium-voltage motors up through specific requirements.) API Standard 541, fourth edition, evolved into a 500 hp, many user specifications separate low-voltage motors from medium-voltage motors at 200 or 250 hp. It is also standard primarily for critical-service applications, with common for medium-voltage motors to be specified with all the detailed testing options for materials and assembled motors found in the third edition. The third edition sleeve bearings. We will refer to them as 841, 541, and 547 throughout this article. (API 546 for synchronous motors is not addressed; there is no other standard for synchronous motors overlapping its scope and use as is the case for induction motors.) Perspectives and guidance on selecting and applying these standards are provided in this article.
TABLE 2. REVIEW OF PETROCHEMICAL STANDARDS.
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IEEE 841-2001 Power up to 370 kW (500 hp) Petroleum, chemical severe duty applications TEFC enclosures Antifriction bearings (ball type) No limits on applications Horizontal and vertical mounting Any area except explosionproof classifications Voltage through 4,000 V (typically 460 or 575 V); 60 Hz Speeds two through eight pole (900 to 3,600 rev/min) Typically die-cast aluminum rotor Random coil windings for low voltage, formed coil winding for medium voltage (2,300 and 4,000 V)

API 547 (2004) 1st Edition, January 2005 Power, 250 hp through 3,000 hp Severe duty applications TEFC and WP-II enclosures Hydrodynamic (sleeve) bearings default General-purpose applications for centrifugal loads Horizontal mounting Typically Class 1, Division 2 area classification Voltage through 13.2 kV (typically 4,000 V); 60 and 50 Hz Speeds two through eight pole 9003,600 rev/min (60 Hz); 7503,000 rev/min (50 Hz) Aluminum OK through 1,000 hp; fabricated copper above 1,000 hp Formed coil windings

API 541 (2003) 4th Edition, June 2004 Power, 500 hp and larger Severe and abnormally hostile environments Any enclosure Hydrodynamic (sleeve) bearings default Critical-service applications for any load condition Horizontal and vertical mounting Any area Voltage through 13.2 kV (typically 4,000 V); 60 and 50 Hz Any speed and number of poles, or adjustable frequency drive (AFD) controls Fabricated copper default, aluminum only on approval Formed coil windings

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The use of standards plays a foundational role in the process of achieving a A GREAT DEAL OF basis for the evaluation of equipment. These present to everyone involved in WORK IN RECENT the process the key requirements that must be met. A great deal of work in YEARS HAS BEEN recent years has been put into revising and improving industry-based motor PUT INTO standards. Users and motor manufacturers have worked together in the REVISING AND standards development, and manufacIMPROVING turers have provided the products to meet these standards. A result of this INDUSTRY-BASED cooperative effort is the overall improvement in the quality of equipment availMOTOR able to all users. Companies or users adapt the standards by providing suppleUser Perspective STANDARDS. ments to adjust for project or local Among the criticisms of standards are requirements that the standard itself the perceived higher first costs and extra cannot or does not address. Using indusor unnecessary requirements. Engineers working for users are under constant pressure to provide try motor standards as a platform to manage equipment TCO lower capital project equipment costs from operations man- and to leverage suppliers competencies delivers consistent agement, who want their production systems to have low equipment installations that cannot be achieved otherwise. first, operating, and maintenance costs. Suppliers, on the other hand, may view standards as onerous or having additive Approaches to Establish Company cost demands, but they are often involved in the process to Motor Standards develop them and may be able to supply the equipment that Motor size and torque capability for the application, complies with them. User engineers will usually determine enclosure type suitable for the area classification, and effithat the ultimate path to profitable systems define standards ciency for minimum operating cost are the first key factors for reliable, effective, efficient equipment that contribute to in selecting a motor to purchase. After that, bearing type (ball or roller or sleeve bearings), followed by any extra high system uptime and consistent product delivery. tests that are deemed necessary should be evaluated. Each There are many ways to deal with these cost pressures. motor purchase must also navigate local and project n The competitive bidding process with bid comparison and equalization is a time-honored and often-used requirements as well as the recommendation of subjectmethod. Price proposals are accepted, and equaliza- matter experts assigned to a project. A user could choose to review each proposal for every tions are made to level the playing field based on compliance to specifications, efficiency, reliability, motor using these factors, but few users have the resources weight, transportation, and other criteria. This to do so. Some motor applications warrant individual process is often weighted heavily toward and focused review, but these are normally motors that are very large or those that perform in critical or unspared service. The upon first cost. majority of motors may not even be purchased by the n Another approach is to use a total cost of ownership (TCO) view to seek lower total overall operating owner company; rather they are purchased by contractors, costs. This is an optimization involving all of the original equipment manufacturers (OEMs), or other third costs together, including first cost (but not neces- parties on their behalf. Defining and using industry-based sarily lowest cost), cost of operation, cost of mainte- motor standards play an important role in simplifying and nance, cost of spares, and cost of downtime. The controlling this process. Key issues are as follows: degree to which standards influence these cost drivers and their effect on TCO is dependent upon the n physical size, horsepower (hp), or torque degree to which the user assigns engineering n enclosure type requirements to the elements of overall TCO value. n bearings: ball or roller and sleeve n Yet another successful approach that has developed is n efficiency the sole supplier or directed volume method. Pricen rotor dynamics and balancing based proposals are accepted, but equal or greater n flexible shafts scrutiny is placed on services, support, and quality n rigid shafts that a supplier may provide with the equipment or n testing product. Similar price points are reached as with n consistency of manufacture. competitive bidding, and it can include a whole host Other things to be evaluated are as follows: of other supplier services and support items. Supplier n use of industry standards versus home-grown costs attributed to the additional services and supspecifications port are recovered from the additional volume that n total cost of acquisition, operation, and ownership is directed their way, along with the reduced adminn first-cost approach istrative costs of a sole supplier arrangement. n manufacturers standard distinguished between special-purpose (critical-service) and general-purpose applications, 250 hp and above. The fourth edition is designed to apply to 500-hp motors and above. It may be used for general-purpose motors, but its depth of criteria and options for design and testing are better suited for more experienced users and critical or unspared applications. It may also be used for applications with special characteristics that may require attention to detail, not necessary with a more common general-purpose motor application. (It has a six-page data sheet.)

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lubrication practices maintenance practices ball- or roller-bearing types to allow or reject n lifetime bearings n shielded bearings n nonshielded bearings. Once a decision is made to use industry motor standards, one discovers that they have overlaps in hp sizes that complicate which standard to use when purchasing new motors. IEEE Standard 841 and API Standard 547 overlap in their motor sizes between 250 and 500 hp. API 541 and API 547 overlap between 500 and 3,000 hp. The overlap regions are shown in Figure 1. Simply choosing a motor based on hp in these overlap regions will generally cause confusion unless other decisions are made to select the proper motor standard.
n n n

The first step to determine which of the three standards best fit is to understand the range of standard motor power ratings, the type of motor enclosures that are preferred or required, bearing preferences, and motor speed ratings (i.e., revolutions per min, based on the number of poles). Voltage is also frequently used in defining a motor specification, but this is not necessary for the following review.
Power Rating Less Than 250 hp

For motors that meet this condition, IEEE 841 is the only standard of the three that applies. As seen in its title, all motors covered by 841 are totally enclosed fan-cooled (TEFC) enclosures, as shown in Figure 2. For 250 hp or greater power, further review is necessary. One or all of the following areas will determine which standard will fit best.
Power Ratings 250500 hp

The Guide API standards use hp to define the scope of their standards, whereas IEEE Standard 841 follows the IEEE norm and leads with the kilowatt rating of motors for its scope in addition to hp. For simplicity, we will use hp in all subsequent discussions.

841 - 547 Overlap 541 All Enclosures and Poles

WP-II and TEFC Four to Eight Pole

547
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WP-II Two Pole

TEFC Two Pole

841

TEFC

547 - 541 Overlap 500 700 1,000 3,000

250

In this range, IEEE Standard 841 and API Standard 547 are the only choices based on current editions of industry standards (see Other Industry Standards section on API 541, third edition). When deciding which of these two standards should be selected, there are three areas for the main focus: enclosure, bearings, and testing. 1) Enclosure: The scope of IEEE Standard 841 covers only severe-duty TEFC motors. API Standard 547 covers weather-protected type II (WP-II) enclosures in addition to larger TEFC motors. These are the only two enclosures covered by 547 (see Figures 3 and 4 for examples). If the WP-II type of enclosure is preferred or required, 841 cannot apply and 547 should be selected. This situation may occur when a replacement motor is needed, because many WPII motors in the 250500 hp range have been placed into service since the 1960s. Although WPII is used for new installations, the TEFC enclosure is often preferred today, as it is available in higher power ratings than in the past. If TEFC is required, the decision process goes to the next step.

Horsepower

1
Power ratings overlap within industry standards.

18

2
Typical IEEE 841 TEFC enclosure. WP-II enclosure.

1) Enclosure: In keeping with the in2) Bearings: IEEE Standard 841 tent of a general-purpose standard, only covers motors with rolling the authors of 547 recognized that element-type bearings (ball or THE USE OF simplicity and limitation of options roller type). API Standard 547 STANDARDS were necessary. The scope of 547 is allows the use of ball bearings therefore applied only to TEFC and with specific approval by the PLAYS A WP-II enclosures. If any other enpurchaser; however, the default closures, such as the totally enclosed bearing requirement is for hyFOUNDATIONAL air-to-air cooled (TEAAC) or totally drodynamic, also known as enclosed water-to-air cooled (TEWAC) sleeve-type bearings. Therefore, ROLE IN THE enclosures, are used, API 541 is to unless the user prefers sleeve be selected. bearings on motors from 250 PROCESS OF 2) Speed power rating: Following to 500 hp, it would follow that ACHIEVING A the limitation on enclosure choices, 841 should be selected as the API Standard 547 also limits the applicable standard for motors BASIS FOR THE size of two-pole motors (3,600 or in this range. If sleeve bearings 3,000 rev/min) to those with true are preferred, 547 is the logical EVALUATION OF rigid (stiff) shaft construction. choice. There are cases where a The actual capability of any given company or project standard EQUIPMENT. manufacturer to meet this will will specify the use of 841, vary. As a result, a limit was set except with sleeve bearings and within 547 for the maximum other criteria that are not covpower rating allowable for two-pole motors. The ered by 841 (e.g., rotor material). This hybrid effective limits are 700 and 1,000 hp, respectively, approach has led to complications that the 841 for 547 two-pole TEFC motors and 547 two-pole standard has intentionally avoided. The 547 stanWP-II motors. Any two-pole motor with a higher dard and its 541 backbone are better suited to power rating 800 hp TEFC or 1,250 hp WPaddress the requirements for sleeve bearings and II must use API 541 (see Figure 1). other criteria associated with larger motors, and In the case of four- through eight-pole motors we recommend its adoption versus a hybrid 841. (1,800 or 1,500 to 900 or 750 rev/min), API 547 3) Testing: API Standard 547 extracts a core group of is limited to 3,000 hp. Again, this is in recognitests from API Standard 541 for its routine test tion of the need to limit 547 to a manageable criteria, whereas 541 has additional tests in its range of motors that would be found in the majorroutine test criteria. The minimum test requireity of general-purpose applications. Any motor ments of 547 or 541 have additional demands versus rating higher than 3,000 hp or with lower than those in IEEE Standard 841. Refer to Table 3 for a eight poles will require the use of API 541. comparison of routine test requirements across all 3) Application: API Standard 547 is defined as a genthree standards. Although 841 has no definition for eral-purpose motor standard that applies to motors tests other than routine tests, motor suppliers may driving a centrifugal load application, having inerprovide optional tests for 841-class motors, such as a tia within limits defined by the NEMA MG 1 complete test or a sound test. When the user desires Part 20 [2]. Applications outside this description testing beyond this scope, then 547 would be the should utilize API 541. Additional consideration logical choice for motors in the 250500 hp range. should be given to motors for applications found Otherwise, the testing requirements of 841 are sufficient to verify basic motor performance. Additionally, the API standards address other testing definitions that 841 does not. These include the tests shown in Table 4. These tests are not normally associated with 841-class motors. The optional tests shown for 541 that are not listed for 547 could be added to a 547 motor requirement if desired. However, these tests begin to expand the scope of a motor beyond general purpose, which was one of the simplifications intended for 547. The user should consider the specification of 541 when multiple tests not listed for 547 are desired. (For further information about API motor tests, refer to [10].)
Power Rating Greater Than 500 hp

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For motors greater than 500 hp, either API 547 or API 541 may be specified. In this power range, there are four main factors that will lead the user to a decision on which standard should be used. These are enclosure, power or speed rating, application, and motor availability.

4
Large TEFC enclosure.

19

under the Unusual Service Conditions section of 547 (para. 1.3) [6] shown in Table 5. These conditions may also have the need for expanded requirements that are not defined within 547 and, for these applications, 541 may be considered in lieu of 547. In the Scope section of the fourth edition of 541 (para. 1.1.1) [5], certain motor sizes and applications are listed that are considered outside the scope of a general-purpose motor. Some of these were specialpurpose applications in the third edition of 541 [9]. See Table 6 for the applications listed in 541, fourth edition. Any motor required to apply or perform in any one of the items shown in Table 6 should have 541-2003 utilized in its specification. 4) Availability: API Standard 547 was developed from API 541 requirements. Its focus is to apply the basic 541 requirements for general-purpose applications and provide a minimum set of added
TABLE 3. ROUTINE TEST REQUIREMENTS. IEEE 841-2001 Measurement of winding resistance* Current* Power* Speed* Measured at no load, rated volts, and speed
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reliability features. As 541 requires the purchaser to identify numerous motor feature choices, it is a more complex standard to apply. When 547 was created, most of these choices were predetermined in the interest of simplicity. This also created a set of requirements that are easily standardized upon. The user community desired a standard that defined requirements that could translate into improved availability for large motors, which exists for motors complying with IEEE Standard 841. With an auditable set of features defined (like 841), API Standard 547 became eligible for the API Monogram program. This program is a qualityand-compliance program that involves auditing a manufacturers quality systems and capabilities to meet an API standards requirements. A successful audit is rewarded by API, with a license that authorizes the manufacturer to use the license number and

API 547 Measurement of winding resistance* Current* Power* Speed* Measured at no load, rated volts, and speed High-potential test (ac)* Locked rotor current*

API 541-2003 Measurement of winding resistance* Current* Power* Speed* Measured at no load, rated volts, and speed High-potential test (ac)* Locked rotor current* Measurement of vibration Insulation resistance test by megohmeter Insulation polarization index test Bearing insulation test (electrical) Bearing temperature rise test Tests of detectors and control devices High-potential test of space heaters and resistance temperature detectors Air gap measurements Shaft voltage and current measurements Inspection of sleeve bearings after testing Extended vibration test requirements Soft foot check prior to test

High-potential test (ac)*

Measurement of vibration

Measurement of vibration Insulation resistance test by megohmeter Insulation polarization index test Bearing insulation test (electrical) Bearing temperature rise test Tests of detectors and control devices High-potential test of space heaters and resistance temperature detectors

*Also defined by the NEMA MG 1: typical minimum commercial test.

20

Not listed by IEEE Standard 841.

API logo on the equipment nameplate, indicating APIs recognition of compliance to the standard. The combination of standardization and API monogram program creates the opportunity for increased user confidence in a motor manufacturers ability to preengineer motors in compliance to 547. With this ability, it is possible for a manufacturer to produce certified 547-compliant motors with shorter production times. It also enables the further possibility for 547-class motors to evolve into a similar market condition as it exists for IEEE 841 motors, wherein they are often available off-the-shelf. These benefits will encourage and make it easier for all parties to favor using API 547 as the preferred API general purpose motor standard, where applicable.
Vertical Motors

bearing applications, IEEE Standard 841 and API Standard 541 discuss the subject of thrust and bearing life. Issues of reed frequency, lubrication systems, and other dimensional requirements are not covered in detail. API Standard 547 specifies vertical mounting as an unusual service condition, and thus does not address vertical motors at all. A detailed discussion of this subject is beyond the scope of this article. We recommend users to take care in selecting and specifying vertical motors and their various configurations by consulting these carefully with the motor supplier. Data Sheets All three of the standards covered in this article have a motor data sheet included to aid the user in applying the standard within their respective intent.
IEEE 841 Data Sheet

None of these standards address the special needs of vertically mounted motors in detail. This type of motor application can be installed using the NEMA P-base, C-face, or D-flange flanges, or foot mounted with shaft down or up. For thrustTABLE 4. OPTIONAL SPECIAL TESTS. API 547 Complete test Unbalance response test Rated rotor vibration test Sealed winding test API 541-2003 Complete test Unbalance response test Rated rotor vibration test Sealed winding test Bearing housing natural frequency test Direct current high-potential test Stator core test Stator inspect before VPI Special surge test of coils Power factor tip-up test Residual unbalance test Balance check with 1 /2 coupling Running tests with 1 /2 coupling Bearing dimension checks before test Bearing dimension checks after test Final assembly running clearance Material inspections

IEEE Standard 841 is intended provide a basis for a standardized motor design that fits the majority of applications,
TABLE 5. UNUSUAL SERVICE CONDITIONS FROM API 547. API 547 Paragraph 1.3 a. a.1 a.2 Exposure to Combustible, explosive, abrasive, or conductive dust Dirty operating conditions where the accumulation of dirt will interfere with normal ventilation (through or over the motor)
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a.3 a.4 a.5 a.6

Nuclear radiation Abnormal shock, vibrations, or mechanical loading from external sources Abnormal axial or side thrust imposed on the motor shaft Altitude or ambient temperature outside the range covered in 1.2 [3,300 ft or 1,000 m; 25 C to 40 C (13 F to 104 F)] Reciprocating or positive displacement loads. Conditions where variations from rated voltage or frequency exceed the NEMA MG 1 limits. Conditions where voltage unbalance exceeds the NEMA MG 1 limits. Operation at speeds other than rated speed. Operation from solid state or other types of adjustable frequency or voltage power supplies for adjustable speed applications. Load inertia greater than or starting conditions more severe than given in the NEMA MG 1. Vertical mounting (motors mounted by flange or feet in a vertical position).

a.7 b.

c. d. e.

f.

Note: IEEE Standard 841 does not list any optional special tests.

g.

21

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requirement from 841 would benefit with little if any need for modificaall parties in the supply of both tion. Accordingly, a data sheet is not purchaser and supplier motor data. required to specify or procure an 841THE compliant motor. However, it is very UNDERSTANDING, common for the engineering compaAPI 547 Data Sheet nies and users to utilize a project or In the context of API Standard 547 SELECTION, AND company standard for 841 basis providing a general-purpose scope for motors that also include a data sheet. API 541-class motors, the data sheet APPLICATION OF These standards are intended to add provided with 547 is less than half the requirements beyond the scope of 841 size of the 541 data sheet. As discussed MOTOR that are unique or specific to the previously and similarly to IEEE 841project or company. The data sheets class motors, a data sheet is not STANDARDS ARE that accompany them are usually very required to specify or requisition a CHALLENGED BY similar in scope and content to the one 547-based motor. found in 841. (This data sheet actually The data sheet in 547 is three pages THE TURNOVER IN originated from the PIP group.) It is a long and has approximately 117 fields simple one-page document, with 40 for purchaser data and 56 for supplier THE ENGINEERING fields for purchaser data and 25 for data. There are default selections supplier data. within this data sheet as there are in WORKFORCE. A primary function of these data 541. Optional choices are presented sheets is to convey motor sizing data for these defaults. The default area and area classification requirements classification for 547 motors is class 1, and to serve as a central collection document for the pur- division or zone 2. However, the group and temperature chasers requirements as well as the motor suppliers motor code definition is left for the user to define. Fields for other design data. Unfortunately, the vast proliferation of vari- areas with selection choices beyond the basic motor rating ous types of data sheets in use prevent the supplier from include the following: standardizing on data desired or required by the user. n service conditions Although these data sheets are usually just page one long n enclosure and not difficult to employ, a standardized format n terminal box n starting n accessories n adjustable speed drive (ASD) operation data (reTABLE 6. SCOPE OR APPLICATIONS quired if or when applicable) FOR API 541-2003. n driven equipment information API 541-2003 Paragraph 1.1.1 n testing. 1 Critical service (user defined, may be The routine test selection area is somewhat redundant, as it unspared or critical to operation or shows the list of eight minimum items required by an API performance of the entire facility or unit it is 547 routine test along with selection bullets next to them. All installed in). of these items must be performed to comply with 547. The presence of the additional selection bullets imply that these 2 Larger than 3,000 hp (2,250 kW) for speeds can or should be selected individually, which is not accurate. 1,800 rev/min and below. Quite simply, the only selection necessary is to choose whether 3 An 800 hp (600 kW) or greater for two-pole the routine test will be witnessed or not. Perhaps this will be (3,000 or 3,600 rev/min) machines of totally revised in the next revision of 547. Special tests are also listed enclosed construction, or 1,250 hp (930 kW) for selection, and other tests may be listed in the other fields. or greater for two-pole (3,000 or 3,600 rev/ Finally, there is a large area on page 3 of this data sheet min) machines of open or guarded confor additional comments, requirements, etc. Although this struction (including machines with WP-I or area exists as filler for this page, it does allow for definition WP-II type enclosures). of additional requirements. The user should be cautioned to avoid attempting to specify a 541 critical-service class of 4 Driving a high-inertia load (in excess of the motor through this area of the data sheet and instead limit load Wk2 listed in the NEMA MG-1 Part 20). its use to API general-purpose type considerations. Even 5 Uses an adjustable speed drive as a source though a data sheet is not required for a 547-compliant of power. motor, use of this data sheet will greatly aid the purchaser 6 Is an induction generator. and supplier in understanding any unique details that are not defined by default features. This data sheet is relatively 7 Is a vertical machine rated 500 hp (375 kW) simple to use and is a significant aid in supporting the or greater. acquisition of 547 class general-purpose motors.
8 Operates in abnormally hostile environments.
Note: API 541 is typically utilized for machines that have one or more of the above characteristics.

API 541 Data Sheet

22

As one might expect, the API 541 data sheet has evolved to capture a greater range of motor and application detail.

The document is six pages long. Page 6 is dedicated for the selection of the various analyses, inspection, and testing options discussed within 541. Half of page 4 and all of page 5 are for motor data supplied after order by the motor supplier. There are approximately 300 fields available for purchaser selections, 130 for supplier data, and another 25 that could fit either of these two areas. This standard requires the purchaser to complete this data sheet to specify details and features (para. 1.1.2) [5]. It is a comprehensive document intended to provide the user the ability to provide complete details for most areas of motor feature selection and definition. With so many available selections to make, it should not be surprising that a solid working knowledge of 541s many requirements and options is necessary as well as clear understanding of the users requirements. The main sections of this data sheet are as follows: n basic data n site data n enclosure n mounting n electrical system parameters n motor-starting criteria n ASD conditions n bearings n lubrication system n special conditions n main conduit box n accessories n driven equipment information n miscellaneous n motor data n stator and rotor repair data n analysis, shop inspection, and tests. This data sheet is designed with current API data sheet structure, wherein purchaser selections are intermixed with supplier data fields or selections that are defined by either the purchaser or the supplier. It is meant to be an interactive document to allow input throughout by key parties to the process from initial preparation by the purchaser through final motor shipment. When completed as intended, this data sheet will provide an in-depth description of motors specified to comply with 541.
Data Sheet Issues

Given the potential for complete transmittal of purchaser requirements via data sheets, it is unfortunate to recognize that significant gaps occur regularly in their use. Although frequent and constant communication between parties involved in data sheet transmittal and use can lead to satisfactory resolution of omissions or conflicts, the effectiveness and efficiency of the process are often compromised. Avoiding these problems upfront will lead to better implementation of the standards as well as better expectations for them to be applied correctly. Following is a list of some of these issues. 1) Data sheet not supplied: Perhaps the largest issue is that data sheets are often not provided to the motor supplier when a request for quotation is sent to them. This is particularly problematic for 541 request for quotations (RFQs), where the data sheet is a required element for compliance and proper

application of 541. There could be several reasons for this issue to exist, but it often occurs when an OEM supplies the RFQ to the motor supplier. The OEM is not frequently provided a motor data sheet by their client, who may be a mechanical equipment engineer not versed in motor standards, or it could simply be an oversight. Regardless of the reasons, this is a common issue that OEMs and engineering companies should address to serve their clients better. It is also possible that API could address this within other rotating equipment standards. 2) Data sheet supplied in portable document format (PDF): The API data sheets were created in the familiar Microsoft (MS) Excel format to allow easy input of data by both the purchaser and supplier. As these data sheets are intended to be interactive, it is difficult to apply the intent of these documents when they are supplied to the supplier in PDF format. Requesting and obtaining them in original format can be difficult if not impossible, which adds a time lag in the transmittal and turnaround of information. 3) Limited knowledge of the standards: From the perspective of the motor supplier, it is clear that the number of engineers creating data sheets far exceeds the number that have a good working knowledge of the standards. This can result in data sheets with missing or incorrect information. It is also clear that API Standard 547 is not well understood, as API Standard 541 is still specified for general-purpose motor applications more often than 547. The 547 standard is still in its infancy and may be misunderstood as a less-featured version of 541 (i.e., 541-lite). Once this is corrected, and 547 becomes adopted more often, improvements in data sheet completion and accuracy should be realized, because the 547 data sheet is simpler and shorter than the 541 data sheet. Ultimately, the best solution for this issue is for engineers and their employers to seek and receive advanced training on selection, use, and application of petrochemical industry motor standards. 4) Missing driven equipment data: Defining a motors feature set normally includes matching it to the application and, in particular, the equipment the motor is expected to operate (drive). For 541 and 547, several areas that need coordination with the motor are as follows: n Motor power or speed rating: Often defined by an OEM (with direction from the engineering company or user-driven equipment specifications) n Sound (noise) level: Usually driven by the engineering company or user requirements for overall equipment sound limits n Mounting: Dependent on the driven equipment n Motor starting: Dependent on the load characteristics of the driven equipment (OEM decides) and the conditions the user defines for operation and starting the equipment (voltage at start-up, driven equipment output valve position during starting, etc.) n Lubrication system: Primarily applicable when external lubrication supply is required or

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FLOW CHART FOR SELECTING MOTOR STANDARDS

Power? Less Than 250 hp 250 hp Through 500 hp Enclosure? TEFC Bearing Type? Ball Sleeve WP-II Any Other Enclosure 500 hp Through 3,000 hp: General Purpose (See Note 1) Enclosure? TEFC rev/min + Power? Four Through Eight Pole, 3,000 hp
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Use IEEE 841

Use API 547

Use API 541

Two Pole, <800 hp Two Pole, 800 hp and Up WP-II rev/min + Power? Four Through Eight Pole, 3,000 hp Two Pole, <1,250 hp Two Pole, 1,250 hp and Up Any Other Enclosure or Number of Poles > 8 500 hp and Up (See Note 2): Critical Service Note 1: API 547 General Purpose Criteria > Centrifugal Load > Load Inertia Within NEMA MG 1 Part 20 > Not an Induction Generator > Ambient Within 25 C to +40 C > Altitude max. 3,300 ft. > Horizontal Mounting > Typically Sine Wave/Utility Power > Direct Coupled Note 2: API 541 Criteria > Application Is in Critical or Unspared Service > Load Inertia Greater Than Listed in NEMA MG 1 Part 20 > Application Is an Induction Generator > Any Ambient Temperature > Any Altitude > Vertical Mounting 500 hp or Larger > Application Uses Adjustable Speed Drive Power > Abnormally Hostile Environment

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specified, i.e., pressurized lube systems (forced or flood lube) or oil mist (purge or pure mist) n Coupling: Who supplies or mounts it? Is a special shaft configuration needed (e.g., cylindrical or tapered)? 5) Missing area classification data: Although the basic area classification data is usually defined (division or class), the applicable group(s) and, in particular, the temperature code (T-code) or autoignition temperature requirement is often missing. The motor supplier is often left to either seek this information or assume it. 6) Inspection and testing requirements: For any given motor requisition, inspection and testing can be defined from several different sources. It is not uncommon for the motor data sheet to have no inspection and test (I & T) selections made or listed. Although there may be no additional I & T requirements beyond the minimum required, there is no clear path to ensure that I & T requirements in other documents are adequately communicated. The motor supplier is dependent on the motor data sheet to define motor requirements in conjunction with motor-specific standards or specifications. This is where any and all motor I & T requirements should be defined. Other Industry Standards Within the petrochemical industry, other standards have evolved or are still in use. This includes previous versions of API Standard 541. The third edition of 541 was written for 250 hp and larger motors. It contained two sections, one for general-purpose and one for special-purpose motors. Both sections required many purchaser decisions to be made on the required motor data sheets. Although the third edition is still in use at this time, the changes made in the fourth edition along with the introduction of API Standard 547 provided a much clearer path for the user to identify and choose between general-purpose and critical-service (special-purpose) standards. Although there is still a lack of understanding among many motor specifiers with regard to the correct application and use of the standards, future use of them will gradually expand and help simplify motor standard specification and motor features selection. Because of the great number of decisions required in the third edition, the PIP organization developed the PIP ELSMT02 motor standard, which served as an overlay standard to provide a set of predetermined decisions for 541, third edition. This PIP standard and its related ELSMT03 for special-purpose motors have been withdrawn since the introduction of 541, fourth edition, and 547. PIP ELSMT01 was also developed as an aid in applying IEEE Standard 841 and may be found in use as well. Another standard that is sometimes presented is American National Standards Institute (ANSI) C50.49 for large motors. This standard was developed for the power industry, and it contains requirements beyond that of the NEMA MG-1 Part 20 but is generally less stringent than those of 541 or 547.

Conclusions The understanding, selection, and application of motor standards are challenged by the turnover in the engineering workforce throughout the petrochemical industry as well as by the changes due to evolution of motor standards, revised typically on five-year cycles. The current standards available to engineers in the petrochemical industry offer the best consolidation of best practices for any industry. There are overlaps in the motor sizes they apply to, necessitated by the variation in user processes and procedures in application and selection of motors. IEEE Standard 841 and API Standard 541 now have API Standard 547 to fill the gap often cited between them. API 547 provides a simplified approach to specification of large motors for general-purpose applications. Also, through the API monogram program, following an in-depth quality and capability audit, manufacturers will be able to obtain a license to display the API logo on their API 547 motors. Users are likely to find preengineered API 547-compliant motors with shorter delivery times and possibly from off-the-shelf inventory in the future. This will provide users the simplicity and availability of large motors they have come to enjoy from providers of IEEE 841 motors. IEEE Standard 841 is in revision and is expected to be rereleased by 2008. To help users and engineers navigate the process of selecting motor standards, we have provided this simplified guide in verbal format and also in a flow chart. We hope this will aid and advance the use of all these standards and make it easier to choose and apply them. References
IEEE INDUSTRY APPLICATIONS MAGAZINE  JAN j FEB 2009  WWW.IEEE.ORG/IAS

[1] IEEE Standard for Petroleum and Chemical IndustrySevere Duty Totally Enclosed Fan Cooled (TEFC) Squirrel Cage Induction Motors: Up to and Including 370 kW (500 hp), IEEE Standard 841-2001. [2] Motors and Generators, NEMA Standard MG 1-2006, 2006. [3] Rotating Electrical Machines, Part 1: Rating and Performance, IEC Standard 60034-1, 2006. [4] Dimensions and Output Series for Rotating Electrical Machines, Parts 1, 2, & 3, IEC Standard 60072, 1991, 1990, 1994. [5] Form-Wound Squirrel-Cage Induction Motors: 500 Horsepower and Larger, API Standard 541-2003, 4th ed., 2003. [6] General-Purpose Form-Wound Squirrel Cage Induction Motors: 250 Horsepower and Larger, API Standard 547, 1st ed., 2003. [7] J. Malinowski, G. DAlleva, and M. Hodowanec, Petrochemical standards: A comparison between IEEE 841-2001, API 541 and API 547, in Conf. Rec. 2004 IEEE Petroleum and Chemical Industry Conf., p. 206. [8] M. Hodowanec, M. Costello, W. Lockley, T. Griffith, and J. Rama, Introduction to API 541, 4th editionForm-wound squirrel cage induction motors: Larger than 500 hp, in Conf. Rec. 2003 IEEE Petroleum and Chemical Industry PCIC-2003-33 Conf. [9] Form-Wound Squirrel-Cage Induction Motors: 250 Horsepower and Larger, API Standard 541, 3rd ed., 2003. [10] T. W. Paschall, G. Donnes, and B. K. Oakes, Navigating the test requirements of API 541 4th edition, presented at the PCIC-200711 Conf., Calgary, Alta, 2007.

Tim Rahill (tsrahill@baldor.com) is with Baldor-Reliance in Parker, Colorado. Michael C. Fousha is with Chevron in Richmond, California. Rahill and Fousha are Members of the IEEE. This article first appeared as Navigating Petrochemical Industry Induction Motor Standards at the 2007 Petroleum and Chemical Industry Conference.

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