Electric Motor Testing: Offline

Jan Michael B. Castaneda

College of Engineering

University of Rizal System

September 19, 2020

EE 9E – Electrical Equipment Operation and Maintenance

Engr. Rene Ariston

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Abstract

This is a report generated after reading and understanding the offline manner of testing

electric motor. The report consists of the things I learned and understood all through the

presentation while researching at the same time. Mentioned here are the types of tests that

can be conducted on an electric motor offline.

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Introduction

We are in great need of electrical equipment nowadays as they are necessary in providing

power in almost everything we are about to do. That’s why it is also important to maintain and

take care of these equipment.

Background

Motor testing is done to track and find problems in the motor and prevent failures that

may arise because of those. Once damaged, a motor is also believed to run with lesser efficiency

as before. So we do motor testing whether it is online dynamic testing or offline static testing to

increase the life span of an equipment, save maintenance or replacement cost, conserve energy

and ensure safety from unexpected electrical failures.

Online dynamic tests are done while a motor is running while on the other hand, offline

static tests are done while a motor is off.

Offline Motor Tests

 Megger Test

Insulation resistance of an equipment degrades over time and it might cause

equipment failures. This test is one of the most popular among all test because of its

simplicity but it isn’t capable of finding all possible problems in a motor. Megger test

checks and verifies the quality of insulation resistance of an electrical system. The

procedure of insulation resistance test or megger test are given below:

1. First we will disconnect all the line and neutral terminals of the transformer. 

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 2. Megger leads are connected to LV and HV bushing studs to measure Insulation

Resistance IR value in between the LV and HV windings.  

3. Megger leads are connected to HV bushing studs and transformer tank earth

point to measure Insulation Resistance IR value in between the HV windings and

earth.  

4. Megger leads are connected to LV bushing studs and transformer tank earth

point to measure Insulation Resistance IR value in between the LV windings and

earth. 

 Winding Resistance Test

Winding resistance test tracks loose connection and open circuits in a system.

This ensures proper wiring and secure connections.

Before conducting a transformer winding resistance test, ensure that all

equipment to be tested is properly grounded. During the test, it is important not to

remove current or voltage leads while current is still flowing through the transformer.

This will cause an extremely high voltage to develop across the point where current is

broken, which could produce a lethal voltage.

 DC Hi-Pot Test

Hi-Pot is short for high potential. This test ensures that current stays at their

right path and no one flows from one point to another. This also identifies faulty

insulations, stray wirings, spacing problems or unnecessary conductive contaminants. As

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 what I have researched, the basic voltage for Hi-Pot testing is 2X (operating voltage +

1,000V), according to the International Electrotechnical Commission (IEC) 60950

standard.

 Surge Comparison Testing

The surge comparison test finds shorts and insulation weaknesses in coils,

windings, electric motors, generators, alternators and transformers. These faults are

typically turn-to-turn, coil-to-coil, or phase-to-phase. Other problems found by the surge

comparison test include wrong internal connections, wrong turn counts, and more for

DC motors. This test is done using also twice the rated voltage plus 1000 V.

The surge pulses produce a decaying wave form by the oscilloscope channel in
the tester. Each wave is compared to the wave from another coil or to the waves from
the other motor phases. All wave forms display on the touch screen.

The waves are nearly identical if the coils or windings are identical. If one has a
fault or insulation weakness, the wave will have a different frequency from the others
and appear separate.  

Good Surge Test Failed Surge Test

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 Polarization Index (PI) Analysis

 This motor test is used to determine the fitness of a motor. The index is made

up of calculating the measurement of the winding insulation resistance. The PI gives you

an idea of how much dirt or moisture buildup there is, the insulation integrity and how

well the motor operates. For this test, the applied voltage should be kept constant for

10 minutes, with an insulation resistance reading taken at one minute and a second

insulation resistance reading taken at 10 minutes. The ratio between the one-minute

and 10-minute measurements gives you the polarization index.

In Polarization Index Testing, it determines the time necessary for insulation

molecules to polarize, so these can resist the flow of current. Once current is

incorporated to windings, alignment of molecules occurs. The rate of alignment provides

you with an idea of the insulation’s condition. These are the steps when doing

polarization index analysis.

1. Removing external and internal connections

2. Discharging all windings to the grounded value

3. Applying a DC voltage between the windings’ conductor and stator, in which the

value of the voltage is very high

4. Using a Megohmmeter to measure resistance

5. Obtaining readings after one minute and 10 minutes, so the final value can be

calculated accurately

6. Turning the power supply off after obtaining readings

7. Using the Polarization Index Testing formula in calculating final resistance value
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 8. Making sure that the testing period is performed within 10 minutes

 Vibration Test

Vibrations and noises in a motor are usually caused by damaged or loose

bearings/coils, bent motor shafts, loose parts inside the motor, improper alignment,

loose or weak motor base and electrical imbalances. Due to these, problems such as

overheating, internal damage, sparking, and winding faults may arise.

Below is the Vibration Severity Chart which is used to determine the

acceptability of vibration levels measured.

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References

https://carelabz.com/what-is-electric-motor-testing-and-why-is-it-done/

https://www.reliableplant.com/motor-testing-31851

https://carelabz.com/megger-test-performed/#:~:text=The%20Megger%20test%20is

%20a,humidity%2C%20moisture%20and%20dust%20particles.

https://testguy.net/content/276-Transformer-Winding-Resistance-Testing-Explained

https://electrominst.com/test-summaries/surge-comparison-test/?cli_action=1600499933.614

https://medium.com/@manneyd/how-is-polarization-index-testing-effective-for-electric-

motors-a1e3b7361141

https://www.mawdsleysber.co.uk/services/noise-vibration-testing/#:~:text=Noise%20and

%20Vibration%20testing%20is,motor%20failure%20down%20the%20line.

https://www.engineersedge.com/vibration/vibration_severity_chart_13658.htm

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