Modern Testing

on
Motors

Presented by
Jyothi R
Manager
AC motors design
Kirloskar Electric Company
 PRODUCT PORTFOLIO

A.C.Motor D.C.Motor A.C.Generator Switch Gear

Transformer Traction Equipment D.G.Set

2
 WHAT IS TESTING ?

• Healthiness / quality of object under test

• Monitored from initial stages.

3
 QA FUNCTIONS

QUALITY
ASSURANCE

INCOMING FINAL TESTING

INPROCESS
MATERIAL
INSPECTION
INSPECTION

ROUTINE FINAL
TYPE TESTS PRODUCT
TESTS
INSPECTION

4
 TOPICS COVERED
• General flow of motor manufacturing process
with stage wise tests involved

• Significant test while considering motor for

rewinding / repair

• Benefits of VPI impregnation

• Final motor testing- standard /special appl.

5
Manufacturing process
flow

6
 Types of copper used
• Enameled Round copper wires

• Enamelled copper strips

• Bare copper strip for wound rotor

• Hardened copper for cage rotor

7
 FLOW CHART
STATOR COIL PREPARATION
A

INSULATED COPPER STRIPS

TRIAL COIL

INSPECTION OF
COPPER INSPECTION MACHINE TAPING
REWORK
OK
REWORK/REJECT
OK
COIL LOOPING
FINAL SHAPING & TAPING

COIL STRETCHING
TESTING &
INSPECTION
COIL SHAPING REWORK/REJECT
OK
PRE-CONSOLIDATION COIL

A
 Tests on copper

• Dimensional check

• Elongation & Stretch test

• Peel test
• Solvent test
• Electrical resistance @ 20 deg c
• Break down voltage

• Varnish property
9
 Incoming copper and insulation testing
facilities

SL.NO. TEST EQUIPMENT PARAMETERS MEASUREMD

Ultimate Tensile Strength, Elongation,
1 Tensile Tester Adherence of insulating materials and
conductors
2 High Voltage Tester HV Breakdown of insulating Materials
3
Muffle Furnace Composition of insulating materials
4 Ovens Thermal stability of insulating materials
5 Elongation tester Elongation property of round copper wire
6 Peel tester Maximum Peel off property of round copper
wire
7 Abrasion tester Minimum/average abrasion property of round
copper wire
8 Springiness tester Maximum Spring back property of round
copper wire
ELONGATION TESTER

11
SPRINGINESS TESTER

12
PEEL TESTER

13
ABRATION TESTER

14
BREAK DOWN VOLTAGE TESTER

15
INSULATING MATERIALS

16
 COIL TESTING
STAGE/SECTION TEST PROCEDURE

1 AFTER COIL INTERTURN TEST SHALL BE CARRIED OUT ON

FINAL INSULATION TEST INDIVIDUAL COILS AT TEST VOLTAGE=
INSULATION (HIGH FREQUENCY (4U+5)*0.5 KV PEAK
HIGH VOLTAGE TEST

2 AFTER COIL INSULATION INSULATION RESISTANCE MUST BE

INSERTION RESISTANCE GREATER THAN 50M OHM(1000V DC)
MEASUREMENT

17
HV COILS

18
STAGE INSPECTION INSTRUMENTS
(HV TESTER)

19
 POLARISATION INDEX

• IEEE Standard No. 43-2000 covers how the producer

should test, determining Insulation Resistance and
Polarization Index.
•
PI is a variation of the IR test. It is the ratio of IR
measured after voltage has been applied for 10
minutes (R10) to the IR measured after one minute
(R1), i.e.

• PI = R10 / R1
20
• A low value of PI indicates that the windings may
have been contaminated with oil, dirt etc or
absorbed moistures.
PI Condition of item under test
<1.0 Hazardous
1 - 1.5 Bad
1.5 - 2.0 Doubtful
2.0 - 3.0 Adequate
3.0- 4.0 Good
> 4.0 Excellent

• If a very high initial IR reading >5GΩ is found then further

PI tests are not needed.
21
• Winding connections for insulation resistance tests
as per IEEMA 43-2000

• It is recommended, that each phase be isolated and

tested separately. Separate testing allows
comparisons to be made between phases.

• When one phase is tested, the other two phases

should be grounded to the same ground as the stator
core or rotor body.

22
 COIL TESTING

3 After Conductor Measurements to be carried out between

connection resistance phases u & v, ….
measurements Resistance values must be within +/-10% of
design values
Phase resistance values average must be
within 1%

Correctness of Using surge comparison tester at around 5 KV

winding inter turn peak
insulation
Phase rotation Test is conducted with phase sequence tester
test
High voltage DC DC voltage is applied for a min
test For 3.3 coils – voltage applied is 6.0kv
Insulation shouldn’t break down
 COIL TESTING

4 After VPI Tan delta Using Schering bridge tan delta – v

measurement characteristic is measured

Final high voltage Ac voltage of twice the rated voltage in KV

test +1kv to be applied for a minute. Insulation
should not break down
IMPULSE TEST KIT SET UP
 WHAT IS AN IMPULSE
 To simulate the Lightning impulse & Switching surge we
have developed Impulse test kit in R & D Dept.

 A Standard Impulse wave shape to simulate Lightning for

testing purposes is 1.2 / 50 micro seconds. i.e 1.2 is rise
time & 50 is 50 % of decay time.

 Switching surges are created by the opening or closing

of a reactive circuit.

 Switching surge : The Impulse wave used for the test

shall be the 175 / 2500 micro seconds impulse , or
250 / 2500 micro seconds impulse for specific customer
requirements.
 TAN DELTA TEST

• Equipment used :

• Automatic tan delta & capacitance bridge with

standard capacitor
• HV transformer with control panel

• Measurement of dielectric loss is the assessment in

total dielectric loss due to voids & other impurities

27
 In process testing equipments

SL.NO. TEST EQUIPMENT PARAMETERS MEASURED

1 Automatic Tan Delta Tester Delta Tan delta

2 Interturn Coil Short Tester Coil short of HV machines

3 Micro ohm meter Winding resistance

4 Megger Polarisation index
5 High Frequency Tester Rotor coil short
6 Impulse Tester HV machines coil
7 DC High voltage Tester HV coils
8 AC High Voltage Tester-30KV HV machines
9 Surge Comparison Tester LV machines
10 Core loss measuring setup HV/LV machines 28
REWINDING OF HV MOTORS

29
 REWINDING ASPECTS
Steps to be followed for re-winding

 Disassemble the motor and remove the stator

 Remove wound stator from the stator frame

 Remove the complete stator winding from the core.

 Clean the core thoroughly

 Conduct core loss test on stator core 30

 Method of winding removal
• Removal of winding from stator or rotor core:

• Core can withstand upto 400 deg c

temperature-Not recommended

• Pulling out of coils from core- recommended

31
 Core loss test
• Very important test to decide rewinding on
same core

• Check for hot spots on core

• Losses on laminated core- revarnishing of core

32
BURS IN THE CORE

33
VACUUM PRESSURE
IMPREGNATION

34
VACUUM PRESSURE IMPREGNATION
CHAMBER

35
Vacuum pressure impregnation
Vacuum Impregnation Plant
 Vacuum pressure impregnation

 Pre treatment:

• Ensure job is free from dust , oil, grease , metal

particles. Blow dry Compressed air over the job
• Apply silicone based grese where resin costing is not
required
• Preheat the job to above 100 deg c to remove
moisture. Check IR value of the job at 500v dc . >
30m ohm
• Allow job to cool, down to ambient ( 35 deg c)
38
Resin preparation
• Check for viscosity & add diluting solvent

Dry vacuum cycle:

• Job is kept in impregnation tank. I ncase of
rotors vertical.
• Evacuate tank to attain vacuum level of 10torr
• Retain this environment for an hour
39
• Impregnation cycle:
 Using pressure difference resin is admitted slowly in
tank, avoid foaming. Resin above job level
 Job is submerged for an hour
 Positive pressure is applied using nitrogen for an
hour
 Pressure released & resin sent back to tank

• Curing cycle:
 Remove job & allow to drain. Clean surfaces
 Preheat oven to 160deg c & commence curing of job

40
 Flood impregnation
• Impregnation : allow job to stay for one hour
in case of large machines, allowing varnish to
thoroughly penetrate the inner layers.

• Coil cools & contracts , air remaining inside

ratifies & draws varnish assisted by
atmospheric pressure.

41
 comparison
VPI impregnation/ resin poor Flood impregnation/
resin rich scheme

Insulation tapes used at thinner tapes used are

comparatively thicker

Better thermal dissipation Lesser thermal dissipation

Conducted at positive pressure At atmospheric pressure
Coil becomes homogenous Almost homogenous
Cost of poor quality is less comparatively more
Test bed rejections are very limited are nominal
42
Process time for coil Low High
making &
impregnation

Impregnation Global Local

Bonding between core High Relatively low
& coil
Reliability High Relatively low
Re-winding Not possible*** Possible
Cost effectiveness High Low

43
PROCESS PHOTOS

44
CLEANLINESS OF THE CORE

45
SLOT LINER

46
TRIAL COIL

47
 SUPPORT
BLOCK

HIGH TENSILE
FIBRE GLASS CORD

END WINDINGS

48
 ARRANGEMENT OF CONDUCTOR

BOTTOM COIL

SEPARATOR

TOP COIL
TOP PACKER

MAGNETIC
WEDGE
STATOR

ROTOR

TAPERED
COPPER CONDUCTOR
49
SEPERATOR

50
AFTER PLACING OF WEDGE

51
END WINDING PACKING

52
WIRE WINDING

53
PULLED WINDING

54
IMPREGNATED HV STATOR
IMPREGNATED STATOR

56
DAMAGE DURING CORE INSERTION

57
HV TESTING

58
 ROUTINE TESTS of ACM
The following tests are conducting on each machine

 Physical checks on RTD/BTD/SPH/Thermistors.

 Measurement of Winding resistance.
 Insulation Resistance test before High voltage test
 Polarization index.
 High Voltage Test.
 Tan Delta tests.
 Insulation Resistance test after High Voltage test.
 Open circuit Rotor Voltage test.(for slip ring motors)
 Locked Rotor Tests.
 Reduced Voltage running up test.
 No load test.(V,I,pf, Speed,NL kw)
 Measurement of Vibration.
 Measurement of Shaft Voltage.
 Over speed test.
 Measurement of Noise Level
 TESTING MEASURING INSTRUMENTS( MEGGER, H.V.TESTER,
AMMETER,VOLTMETER,SOUND LEVEL METER, VIRATION METER,
NON CONTACT THERMO METER, MICRO OHMMETER, POWER
ANALYSERS,RPM METER)

60
 TESTING MEASURING INSTRUMENTS( MEGGER, H.V.TESTER,
AMMETER,VOLTMETER,SOUND LEVEL METER, VIRATION METER,
NON CONTACT THERMO METER, MICRO OHMMETER, POWER
ANALYSERS,RPM METER)

61
 TESTING MEASURING INSTRUMENTS( MEGGER, H.V.TESTER,
AMMETER,VOLTMETER,SOUND LEVEL METER, VIRATION METER,
NON CONTACT THERMO METER, MICRO OHMMETER, POWER
ANALYSERS,RPM METER)

62
 TESTING MEASURING INSTRUMENTS( MEGGER, H.V.TESTER,
AMMETER,VOLTMETER,SOUND LEVEL METER, VIRATION METER,
NON CONTACT THERMO METER, MICRO OHMMETER, POWER
ANALYSERS,RPM METER)

63
 TYPE TESTS ACM

TYPE TESTS:
The aim of the type tests is to
Demonstrate/Measure the fitness of the products as per
specifications.
Establish the performance.
Provide the performance data for checking subsequent
machines on routine production tests.

The following Type tests are conducted on motor

Temperature rise tests.
Starting Torque and Starting Current tests.
Pullout Torque.
Momentary over load tests
 Modern testing methods
• Direct loading

• Super position method

• Reduced voltage method

65
 VIBRATION MEASUREMENT

TEST MOTOR

Preliminary checks before vibration measurement

• Base alignment
• Base limping
• Rigid mounting
• half key

 Run the machine on no load at base and top speed.

 Measure the vibration at all rated speed in mm/second at both the bearings and also for
cooling unit if applicable and at the following positions.
a) Horizontal
b) Vertical
66
 NOISE LEVEL MEASUREMENT

 Run the machine on no load at Rated speed.

 Measure the noise level at all rated speed in dB(A) at a distance of 1 mtrs in 12 positions and switch
off the motor measure the ambient noise

 Acoustic chamber for small machines

  67
 Special tests
• High voltage test with explosive gas on stator
winding

• Gas testing for rotor

• Flame proof test

• IP 55 test for second numeral

• Testing motors for radiation zone

68
 Reliability centered
maintenance
• Condition monitoring technologies

• Remote control panel for monitoring

• Cloud system monitoring for larger plant

69
 "Quality is never an accident; it is always the result of high
intention, sincere effort, intelligent direction and skillful
execution; it represents the wise choice of many alternatives."
- Will A. Foster