Challenge: Mitigate ignition risks
The customer faced a critical operational need for a reserve motor capable of seamless integration as a drop-in replacement for their original motor, which had failed. The key difficulties involved not only meeting the high power demand of 7.900 kW at 1482 min⁻¹ and 5.500 V but also ensuring the motor’s design complied with strict explosion protection requirements for use in the hazardous gas zone 2 environment typical in oil and gas facilities. Additionally, the existing infrastructure imposed rigid dimensional constraints, including an axle height of 800 mm and compatibility with the original motor’s cable entry positions. Weight was also a concern due to foundation load limits, and the motor needed to be equipped with a nitrogen purge system to mitigate ignition risks during startup under high thermal loads. These diverse and stringent technical demands posed a significant engineering challenge.
Solution: Combining power optimization with enhanced safety features
MENZEL responded with a tailored design for a medium voltage three-phase squirrel cage motor that combined power optimization with enhanced safety features. The motor was engineered with a project-specific dimensioning approach to reduce the total weight to 24.800 kg, significantly lighter than the original motor’s over 33-ton weight, enabling easier handling and reducing stress on the existing foundations. To comply with the explosion protection classification II3G Ex nA IIC T3 Gc, MENZEL implemented a non-sparking design with specialized sealing solutions throughout the housing and installed a dedicated control cabinet and purge connections to allow nitrogen flushing prior to startup. This pre-start purging reliably prevents the presence of any ignitable gases within the motor, thereby eliminating any ignition hazard even under elevated starting temperatures. The cooling type is IC 616, incorporating an air-to-air cooler that ensures efficient heat dissipation specific to compressor operation. Furthermore, MENZEL precisely matched the main terminal box adapter to replicate the original motor’s cable entry position, facilitating straightforward installation on-site without the need for costly rewiring or modifications. To guarantee rapid future replacements and maintenance, a custom identical intermediate frame was designed, enabling exchangeability with both this new motor and older models without alterations to the existing foundation. This comprehensive solution gave the customer a technically superior reserve motor that aligns with their operational and safety requirements while minimizing downtime and integration risk.
Technical Data
- Motor Type: MEBKSLN800-04
- Rated Power: 7.900 kW
- Rated Voltage: 5.500 V
- Frequency: 50 Hz
- Rated Speed: 1482 min⁻¹
- Number of Poles: 4
- Frame Type: IM 1001 (IM B3)
- Protection Class: IP 55
- Cooling Type: IC 616
- Weight: 24.800 kg
Our Expertise: Your Advantage
This project exemplifies how MENZEL’s deep engineering know-how translates into a decisive benefit for you as a customer: you receive a technically optimized, lighter motor that conforms exactly to your existing installation parameters, eliminating the need for foundation or cabling modifications. The integration of a specialized nitrogen purge system is a prime example of how we tailor safety functionality to meet stringent industry standards, protecting your personnel and equipment in explosive atmospheres. By delivering a solution that balances performance, weight reduction, and enhanced non-sparking design, MENZEL ensures that your compressor drive operates reliably with minimal risk and maximum uptime. The ability to rapidly exchange motors via an identical intermediate frame further reduces your maintenance downtime and lifecycle costs, securing your operational continuity in harsh environments.
Do you face similar challenges with demanding compressor applications in hazardous zones, or require a custom-fit reserve motor that meets both operational and safety demands? Contact us directly to discuss your requirements with our engineering team and discover how our tailored solutions can safeguard and optimize your operations.
