SPECIFYING A MACHINE

By Andrew J. Spisak
Electro Mechanical Engineering Associates. Pittsburg, Pa. Introduction A well-written specification for a machine is essential from both the manufacturer and user standpoints. For the manufacturer he knows the requirements for the machine he is to build and for the user he has defined a machine that will meet his needs. Both parties are protected by the specification. The manufacturer has fulfilled his obligation by compliance with the specification and the user gets the product that meets his requirements. The potential for an adversarial situation that could lead to litigation is thereby mitigated. The following guidelines are directed towards the specification for new machines. However, they can also be applied to modifications to existing machines such as up rates where particular objectives are to be met. For electric machinery, specifications covering rewinds and overhauls can also be very useful. Specification Objective A good specification starts out with a clear statement of its intent. It is essential for the writer to be able to have this understanding. In doing so he sets the tone for the entire specification, He must not only understand the machine function and its intended output but also the conditions under which it must operate. The writer must also decide on how much design detail, if any, is to be contained in the specification. One option would be to prepare a purely functional specification. In this case the writer focuses on the machine output at all operating conditions. In this approach the machine is viewed as a black box given certain inputs with the expectation of certain outputs while being subjected to whatever outside forces prevail. Another approach would be to specify certain design details. In this case the writer knows what works and specifies it accordingly. The danger in this approach is that it places what might be viewed as unnecessary responsibility on the user. Furthermore it might preclude design features that would be better for the application. Accordingly it is recommended that specification be written for the most part from a functional standpoint and design details specified only when deemed essential to achieve a machine that meets the requirements.

Page 1

0-7803-7091 -0/01/$10@2001 IEEE

555

Specific Requirements In this section of the specification the writer should delineate the specific requirements for the machine. For rotating electrical machinery this would include:
e e
e
a

temperature limit on the electrical windings but require a higher temperature insulation class. When this is done there should be a clear statement showing that an exception has been taken to a referenced standard. It should also be recognized that we are working in a global economy. When purchasing equipment from foreign suppliers the specification writer must be aware of the applicable standards that are normally used in that country. Work done in developing guidelines for large combustion turbine driven generators revealed some interesting aspects regarding ANSI standards and the British and IEC standards. In that study some of the more notable observations found were:
e

e e

e e

Kilowatt, KVA or horsepower output. Number of starts Rate at which the load is applied Duty cycle Design basis upset condition Upset conditions that are expected to occur frequently (several times per year) Upset conditions that are expected to occur occasionally (a few times over the life of the machine) Environmental conditions indoor, outdoor, air quality, severe weat her conditions , salt spray, etc. Method of cooling - open ventilated, totally enclosed water to air cooled (TEWAC), etc. If open ventilated, what is the maximum air temperature? If TEWAC, what is the maximum water temperature for cooling? Expected useful life.

Existing Standards Reference to existing standards can be very helpful. Care must be taken that they do not conflict with other requirements set forth in the specification. For example, some users specify a maximum Page 2
556

Although the ANSI standards did not recognize direct cooling on air-cooled generators both rotors and stators were being manufactured with direct cooling. e The European standard for the generator capability at variable inlet temperatures is to be set by the maximum temperature as seen by the embedded temperature detectors. This could result in excessive temperature at the hottest spot since the difference also varies with load. e None of the standards address environmental issues such as air or water quality.

standards allow the losses to be understated by as much as 10% and thereby allowing some overstatement of the efficiency.

IEC

Measurable Acceptance Limits Witness Points

Specific Design or Processing Requirements By specifying a certain design feature or processing method the specification takes on the responsibility for those requirements. This practice should be avoided to the greatest extent possible. However, there are cases where experience has shown that certain features will work while others will not. In those cases there is no choice but to provide specific requirements. For electric machinery there may be a need to specify certain materials. For example, some materials for non-magnetic retaining rings on gas or steam driven turbines have proven to be susceptible to stress corrosion cracking. To avoid this problem 18-18 austenitic stainless steel should be specified.

Where possible measurable acceptance limits should be specified. These limits should apply to machine features deemed critical for reliable operation. For electric machinery these limits could include:
0

0
0

Maximum allowable operating temperature on various components. Maximum vibration. Minimum efficiency at meaningful operating conditions. For high voltage machines partial discharge activity (PDA) limits could be appropriate. Maximum temperature differentials on the stator core while undergoing inter-laminar insulation testing.

For high voltage machines the specific recommendations could be in order to avoid corona. This could include minimum spacing between coils especially where the voltages between coils is near phase-tophase potential. In these machines it is necessary to maintain good contact between the stator iron and the coils. In this case it would be prudent for the specification to offer one or more methods that have been proven to maintain coil tightness in the slots.

The specification should state what tests must be performed. Where deemed necessary, witness points should be specified to not only verify that critical measurements were taken and within acceptable limits but to also provide assurance that they were made correctly. It should also be recognized that some critical features might not be measurable or verified on the completed machine. In that case a witness point should be specified at a point in manufacture where it can be verified. For example, the specification might require that the coils in a high voltage machine be tight in the slots. This would be difficult to verify

Page 3
557

without actually installation.

witnessing

their or

Special Environmental Operating Conditions

The specification should point out any environmental or operating conditions that could affect its operation. Air quality and weather conditions will have a major effect on how electric machinery is housed and ventilated. The temperature range over which the equipment must operate is also important. High temperatures will affect the insulation life. Extremely cold temperatures could affect bearing operation or even mechanical failure of components susceptible to brittle fracture. Machines subjected to a wide range of loading or cyclic duty generally have a shorter life and require more maintenance than those subjected to steady and continuous loading. The specification should clearly state what operating conditions are to be expected. It . is recommended that goals for availability and reliability be established along with the time between scheduled outages for maintenance. Summary The bottom line .for a good specification is that it results in a machine that meets its objectives over an acceptable useful life and with minimum maintenance. By carefully defining the functional requirements and expectations the specification goes a long way in achieving these objectives. Where

available existing standards should be cited while at the same time noting any exceptions. Unless deemed necessary to assure that the equipment will perform as intended, the specification of materials or other design details should be avoided. Where possible provide measurable criteria and/or limits for acceptance. Clarity is of utmost importance. Any ambiguity can lead to misunderstanding that could result in a machine that does not meet the requirements. Extreme care must be taken so as not to have information in the specification that conflicts with other parts. The best way to get a machine that meets expectations and avoid future litigation is to provide a clear, understandable specification.

Page 4
558