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HE COMMITTEE ASSOCIated with the development of the American Petroleum Institutes (API) Standard 541,

Form-Wound Squirrel Cage Induction Motors 500 Horsepower and Larger, fourth edition, realizes that many individuals working with this standard may not have experience with or knowledge of motor theory, operation, and testing. For this reason, the standard includes a design guide to assist with the decisionmaking process. This article further addresses the testing requirements of the standard by explaining when and why these tests are required. The sequence of topics in this article follows the paragraph numbering for API 541, fourth edition. API Standard 541 Fourth Edition API 541, fourth edition [4], covers the mini STOCKBYTE

mum requirements for the production and purchase of all form-wound squirrel cage

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BY TIMOTHY WAYNE PASCHALL, BRYAN K. OAKES, & GARY DONNER

Digital Object Identifier 10.1109/MIAS.2008.930896

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Navigating the test requirements of API 541 fourth edition


1077-2618/09/$25.002009 IEEE

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induction motors above National Electrical Manufacturers Association (NEMA) 440 frame sizes (nominally 500 hp and larger) for use in petroleum industry services. Because of its success, API 541 has become the recognized standard for purchasing high-quality, high-performance motors used by most large industrial and utility purchasers throughout the world. The standard may be applied to adjustable-speed motors and induction generators with appropriate attention to the specific requirements of such applications. It also gives information on electrical and mechanical design features such as insulation systems and accessories. By using the information in this article, users should be able to make more informed decisions about specifying the testing for their API 541 fourth edition motors. Test Procedures from API 541 Fourth Edition
Balance Check with Half Coupling (API 541 Fourth Edition Paragraph 2.4.6.3.3)

of API 541, which shows the calculation method to verify that the residual unbalance amount is within the tolerance of Ub. Ub 4Wr =Nmc , (1)

This test is typically specified for two-pole motors of 2,000 hp and larger. The test demonstrates that the coupling does not introduce additional unbalance into the rotating assembly. This procedure is completed in the same time frame as the residual unbalance test. When selected on the data sheet, the vendor must determine if this testing is practical for the motor facility. If it is practical to install the coupling on the shaft in the balance machine, then this test will provide important data on the complete balance of the rotating assembly. If there is an increase in the unbalance because of the addition of the half coupling, these data will be reported to the purchaser. Corrections to the balancing of the rotating assembly and/or the half coupling must be mutually agreed upon.
Residual Unbalance Plot

where Ub is the residual unbalance (oz-in), Wr is the weight (lb) on each bearing journal (1/2 of the rotating assembly weight), and Nmc is the motor rotational speed in revolutions per minute (not the rotating assembly balancing speed). The residual unbalance can be plotted on a polar graph to show the position of the unbalance that consists of an amplitude and angle. If the residual unbalance for any plane is exceeded, then the rotor should be totally rebalanced, and the residual unbalance testing should be repeated in all planes. The testing shows the quality of balancing of the rotating assembly before the motor is built and confirms that the balancing process is completed properly. This procedure is a time-consuming process but can give important information on critical service motors. The balance may change over time, but the amount of change can be calculated if the residual unbalance is documented during the building process. In Figure 1, a residual unbalance report shows the position of the residual unbalance, balance tolerances, and actual residual unbalance and specifies the balance plane being measured.
Running Tests with Half Coupling (API 541 Fourth Edition Paragraph 4.3.1.6.2)

This is a recommended test for all two-pole and four-pole motors operating above their first lateral critical speed.
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Residual Unbalance Verification Test (API 541 Fourth Edition Paragraph 2.4.6.3.6)

Actual Residual Unbalance: 0.091 (oz-in) Allowable Residual Unbalance: 0.894 (oz-in)

(0.42, 18) (0.42, 322)

This balance verification procedure is recommended for all motors with two or four poles and for six-pole motors above 3,000 hp. This test is not necessary for motors having eight poles or more. The purpose of this test is to demonstrate that the rotating assembly has been correctly balanced. This test defines the amount of unbalance remaining in the rotating assembly after completing the balancing procedures. A known trial weight (2 Ub) is added to the rotating assembly at a specific location and moved in six or 12 equally spaced locations along the same radius to determine the residual unbalance in one plane. Refer to Appendix D

(0.41, 77) 270 (0.38, 268) (0.02, 12) 90

(0.38, 136)

(0.40, 201) Balance Plane: Drive End


Residual unbalance plot.

180

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The purpose for this test is to check the motor vibration with the coupling half installed on the motor shaft. If it is not practical to install the coupling half on the shaft in the balance machine, then this test should be reviewed as an alternative. Balancing or testing with the half coupling can be selected on the data sheets that are provided to the vendor. Vibration readings are recorded at one-fourth voltage with and without the coupling installed. This shows how the rotating assembly is affected by the prebalanced coupling. The magnitude of the vector change in the 1x vibration on the shaft and bearing housing shall not exceed 10% of the vibration limits per API 541 fourth edition. Once the data at one-fourth voltage are recorded and verified, the voltage is increased to the rated voltage of the motor. A full set of vibration readings are recorded to verify that the data are within the API 541 fourth edition limits listed in Table 1. If either test exceeds the limits specified by API 541 fourth edition, then the vendor and the purchaser shall mutually agree on the appropriate corrective actions. Also, when selected on the data sheets, the coupling must be mounted for the unbalance response testing. This item can be selected on the data sheets to specify the proper testing along with the selection for the unbalance response test.
Slow Roll Runout Measurement (API 541 Fourth Edition Paragraph 4.3.3.1)

adds to the overall vibration, the user may experience unnecessary vibration trips of the motor. API 541 fourth edition requires slow roll runout measurement documentation at two steps during the manufacturing process. The first measurement occurs with the rotor supported in v-blocks at the journal centers prior to motor assembly. The runout data are obtained by using proximity probes and dial indicators to measure at the center line of each probe track while slowly rotating the rotor assembly a full 360. The total mechanical and electrical runout at this inspection point should not exceed 25% of the allowed peak-to-peak unfiltered vibration amplitude. A motor operating at 3,600 rev/min has a peak to peak vibration amplitude limit of 1.50 mil; hence, the slow roll limit in v-blocks is 0.375 mil. The slow roll runout levels are also measured in the assembled machine with the rotor operating at speeds between 200 and 300 rev/min. The total mechanical and electrical runout at this inspection point should not exceed 30% of the allowed peak-to-peak unfiltered vibration amplitude. A motor operating at 3,600 rev/min has a peak-to-peak vibration amplitude limit of 1.50 mil, so the slow roll limit at test is 0.45 mil.
AC High-Potential Test (API 541 Fourth Edition Paragraph 4.3.2.1.c)

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This test is recommended for motors having sleeve bearings and proximity probes or provisions for probes. Slow roll runout measurements are obtained using noncontact proximity probes that are mounted in each bearing cap. There are two probes in each cap mounted 45 from vertical. Proximity probes operate on the eddy current principle and measure shaft vibration and position relative to the bearing housing. The slow roll runout measurement includes both mechanical and electrical sources of vibration. Measurements are recorded at a low speed range so that the influence of dynamic vibration is eliminated. The mechanical runout may be attributed to nonconcentric surfaces, bows, and surface imperfections, whereas the electrical runout may develop as a result of residual magnetism, residual stress concentrations, precipitation hardening, and metallurgical segregation. The value of the slow roll runout data can be seen when compensating the shaft vibration for runout. Slow roll vectors may add or subtract from the overall vibration levels. This is of importance when determining levels for motor alarm and shutdown. If the slow roll vectors subtract from the overall vibration, then the motor may be operating at higher vibration levels than desired. If the slow roll vector
TABLE 1. API 541 FOURTH EDITION VIBRATION LIMITS. Speed Unfiltered Bracket (ips) 3,600 1,800 1,200 Shaft (mil) 3,600 1,800 1,200 1.50 0.30 1.20 0.50 0.10 0.10 0.10 0.10
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The ac high-potential test consists of the application of a voltage higher than the rated voltage for a specified time to determine the adequacy against any breakdown of insulation materials and spacing under normal conditions (NEMA 3.1.2 [3]). Voltage is applied from all the leads of the winding to ground (stator core) or phase to phase. If a short occurs through the insulation, excessive leakage current flows and stops the test. If the test is stopped because of excessive leakage current, the test fails and the winding is damaged and will need repair. The test is typically conducted using 60-Hz ac voltage. The standard highpotential voltage is twice rated plus 1,000 V rms for 1 min as a final check per NEMA [3]. This test is used to verify the integrity of the ground wall insulation. This is considered a destructive test that stresses the insulation and damages insulation if the test is failed. The conservative approach is to first perform a megger test. If that test is good, then it very gradually increases the value of the ac high potential while watching for a current runaway. In reality, an ac high-potential test can do less damage to a winding because it places the stress across the capacitive portion of the winding. The dc test places the stress across the resistive portion of the winding and can cause more damage very quickly.
Polarization Index Test (API 541 Fourth Edition Paragraph 4.3.2.1.d)

1x

2x

The polarization index test is beneficial for determining the ground wall insulation condition. It is the ratio of the 10-min to 1-min insulation resistance test using a dc high-potential source Polarization index Resistance after 10 min : Resistance after 1 min

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Trending the polarization index of a motor provides an indication of the condition of the winding. The recommended

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minimum value of polarization index for motors is 2.0, if the value is greater than 4.0, indicating that the insulation is in excellent condition. However, todays insulation systems have improved so it is now possible to get a 1-min reading that is above 5,000 MX and does not change during the remainder of the test time. When this occurs, it is recommended that the phases be separated at the winding neutral when accessible and retested. During the retest, if each phase archives 5,000 MX in 1 min or less and remains unchanged during the remaining test time and it has a resistance value that is within a few percentage points of each other, then the polarization index should be disregarded. If there is a large difference between the polarization index readings of the individual phases, additional high-potential testing should be done to find the problem. API 541 fourth edition requires the stator winding polarization index values be measured before and after the highpotential test of the stator winding. These values provide an excellent baseline for future trending and comparison. See IEEE Standard 43 [7] for additional details. The polarization index is useful in evaluating windings for the following: n buildup of dirt or moisture n gradual deterioration of the insulation (by comparing results of tests made earlier on the same machine) n fitness for over potential tests n suitability for operation.
Bearing Insulation (API 541 Fourth Edition Paragraph 4.3.2.1.g)

the bearing by placing a sheet of insulation paper between the shaft and the bearing. Use a filament light bulb connected in series with a standard 110 V ac power supply, and place one lead to the insulated bearing and the other lead to the frame or bracket. If the bulb does not light, the insulation is considered acceptable. The low-voltage ohmmeter method requires isolating the bearing from parallel current paths by insulating the shaft from the bearing and attaching one lead from the ohmmeter to the shaft and the other to the frame to measure the bearing insulation resistance. With the meter on maximum ohm scale, the circuit must be shown as open. The megohmmeter method also requires isolating the bearing from the shaft and then attaching leads of a 500 V dc megohmmeter between the shaft and the bearing bracket. Energize the megohmmeter to determine the bearing insulation resistance. With the meter on maximum ohm scale, the circuit must be shown as open.
Bearing Temperature Rise (API 541 Fourth Edition Paragraph 4.3.2.1.h)

Motors specified to API 541 fourth edition have two insulated bearings with one removable ground strap, usually on the drive end bearing. Insulating the bearings is required to prevent small voltages generated in the motor shaft from producing enough current flow in the bearings resulting in erosion of the bearing metal. A ground strap supplied with insulated bearings must be disengaged prior to testing the integrity of the insulation. The bearing insulation test is a routine test and performed on all motors. The sources of shaft voltages are as follows: n magnetism in the rotor, shaft, bearings, end brackets, etc. n a closed, low reluctance magnetic circuit that includes the bearings n capacitive coupling of voltages from inverters n stator core dissymmetry. Circulating bearing currents can quickly damage a bearing by causing the surface of the bearing or shaft that the bearing supports to become fluted, as seen in Figure 2. If left unchecked, circulating shaft currents can destroy a bearing in less than 24 hours of operation. The most reliable way to inspect the bearing insulation is to have the motor at rest and uncoupled from the driven equipment. IEEE Standard 112 [2] provides three methods for checking bearing insulation resistance. The methods are the light bulb method, the low voltage ohmmeter method, and the 500-V megohmmeter methods. The light bulb method requires an isolation of the bearing from parallel current paths by isolating the shaft from

The bearing temperature rise test is a routine test and performed on all machines. Depending on the bearing type, its purpose is to determine the following: n The bearing is correctly seated. n There is appropriate contact surface between the shaft and bearing (Figure 3). n The bearing is able to produce an appropriately large enough oil wedge to support the shaft on oil at running speed. The temperature rise test is performed by measuring the total temperature rise of the bearing metal, at regular intervals, until the temperature stabilizes. On sleeve bearings, the temperature measurement is taken in the bottom of the bearing shell at a location that is not more than 0.5 in from the minimum oil film. For antifriction bearings, the temperature measurement is taken at the outer race of the bearing. Thermometers, thermocouples, resistance temperature devices (RTDs), or other temperature detectors may be used. Under no-load conditions, the

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Bearing damage due to shaft currents.

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lower the temperature rise that the bearing stabilizes at, the better. The maximum temperature rise, at full load, that is allowed at rated operating conditions is 93 C per paragraph 2.4.7.1.2 of API 541 fourth edition.
Bearing Dimensional or Alignment Checks (API 541 Fourth Edition Paragraphs 4.3.2.1.i.j. and k)

The dimensional and alignment check for sleeve bearings is recommended for all motors. A bearing inspection is recommended before and after all running tests. Some choose not to conduct a final bearing inspection as there are risks involved in taking apart a motor that is operating with stable bearing temperatures. The risk of removing the bearings and then reinstalling is that without another vibration test one cannot confirm the motor is still operating the same as it was prior to the bearing removal. This inspection is invaluable and is recommended especially for two-pole motors operating above their first resonant speed (lateral critical speed) to ensure the bearings were not damaged when the rotor speed passed through the resonance. The inspection first consists of a sketch or photograph of the bearing contact pattern (Figure 3). The contact between the shaft journal and the bearing bore should cover a minimum of 80% of the axial length and be symmetrical with no edge loading. The second inspection consists of measuring the journal to bearing clearance and the bearing shell to bearing cap crush. Measurements are made by using a special extruded

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plastic thread material that has a graduated scale printed on the envelope. Measuring bearing clearances and crush with the extruded plastic thread requires the removal of the bearing cap and top section of the bearing. For bearing clearances, strips of the extruded plastic thread are laid across the journal diameter of the shaft. The top bearing section is bolted to the bottom bearing section. When the bearing bolts are tightened, the pressure causes the plastic thread to be flattened. Then, the bearing cap is installed and tightened, which will provide the proper clearance that the bearing will see during the operation. The less clearance there is, the greater the flattening and the wider the plastic thread strips. The numbers on the graduated scale indicate bearing clearance in thousandths of an inch, as shown in Figure 4. Measuring the bearing housing to the bearing outer diameter (OD) occurs by placing plastic thread strips on the bearing OD. Then a shim is placed between the bearing cap and bearing housing to provide a known clearance between the housing the bearing OD. The bearing cap is tightened down to crush the plastic thread. The cap is then removed to view the width of the plastic thread on the OD of the bearing. The plastic thread is visible on the bearing OD as shown in Figure 5 and can then be measured for a direct comparison with the graduated scale on the envelope. The value that is measured on the bearing OD is then subtracted by the known shim thickness to determine the crush on the bearing OD. At an ambient temperature, the crush fit between the outside of the bearing shell and the bearing housing should have zero clearance to an interference fit of 0.002 in. The journalto-bearing clearance will vary based on the speed of the motor and bearing size, but a general rule is 0.0010.0015 in of diametric clearance per inch of the journal diameter.
No Load Vibration Test (API 541 Fourth Edition Paragraph 4.3.3)

This test is a standard vibration test for all API 541 motors to verify the motor vibration is within the limits of API 541 as tested on a seismic mass. A seismic mass is a massive foundation with a mounting plate mounted on springs and damper, which allows for the motor to be isolated from the environment and allow for the evaluation of the motor performance. One indication that a foundation is massive is that the vibration amplitudes of the foundation (in any direction) near the machine feet or base frame are less than 30% of the amplitudes
3
Sleeve bearing wear pattern inspection.

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4
Clearance measurements on the shaft OD. Clearance measurement on the bearing OD.

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that could be measured at the adjacent bearing housing in any direction as defined in API 541 fourth edition. The motor is placed on the seismic mass, and a check for soft feet is performed with a dial indicator to ensure that each foot does not deflect greater than 0.001 in, as it is loosened and then retightened. If deflection exceeds this value, shimming will be required to minimize the foot deflection to the above level. Once the soft foot is confirmed and acceptable, the motor is tested at full voltage to simulate the motor in service but at no-load conditions. The stator winding and bearing temperatures are monitored to verify that they do not exceed the design criteria. The vibration is recorded during the testing until the bearing temperatures are stable to within 1 C per 30-min readings. After the bearing temperature stabilization point is determined, the motor operates for 1 h while recording the vibration and temperatures. This testing also demonstrates the bearing performance with respect to excessive noise or lubrication leaks. The vibration criteria are defined in API 541 fourth edition and are listed in Table 1. In some cases, only the bracket vibration is recorded because noncontacting probes or provisions for noncontacting probes were not specified on the motor. The vibration must be recorded in the horizontal, vertical, and axial directions on each of the bearing housings. The vibration data should include unfiltered amplitudes and filtered amplitudes at these defined frequencies: one-half running speed, one-time running speed, one-time running speed phase angle, two-time running speed, one-time line frequency, and two-time line frequency. The temperature and vibration data should be in 30-min intervals during this test to verify the quality of the motor. For two-pole motors, a special set of data is required to be recorded for 15 min. This vibration is recorded continuously for 15 min in 1-min increments to capture the modulation of the vibration and cannot exceed the limits of API 541 fourth edition. On request, the customer can obtain spectrum plots for each vibration point that is recorded during the mechanical run.
Hot-to-Cold Vibration Test (API 541 Fourth Edition Paragraph 4.3.3.10)

resultant vector change, an alternate method shall be to cool the motor back to ambient temperature, repeat the cold uncoupled, repeat the heat run, and repeat the hot uncoupled. The variation between the first and second hot uncoupled vibration readings must be within 10% of the allowable limits of the API 541 fourth edition shaft vibration. The hot-to-cold change is completed on most motors that undergo dynamometer testing due to the manufacturing setup and testing equipment limitations. This procedure is important to verify that the motor vibration is not affected by the change in temperature.
Stator Core Test (API 541 Fourth Edition Paragraph 4.3.4.1)

This test is a quality test for the stator core plate insulation and ensures that the core plate insulation is not damaged. The test is conducted on the stator prior to the insertion of the stator coils. Rated flux is maintained on the stator core for a minimum of 30 min while continuously monitoring stator temperatures. Deficiencies are defined as any core location that is 5 C above the adjacent core temperature. This test should be specified by the user only for unspared applications or where the motor will be inaccessible for easy repair or replacement.
Surge Comparison Test (API 541 Fourth Edition Paragraph 4.3.4.2)

This recommended test is performed to determine the winding insulation condition. This test detects turn-to-turn, coilto-coil, and phase-to-phase insulation defects. The risk of not doing the test is that any marginal turn-to-turn insulation in the winding may not fail during the running tests but may fail in operation when the motor is subjected to mild power system surges. The test voltage should be agreed upon with the vendor to avoid a premature failure. Surge comparison testing is based on the principle that in a stator with no defects all three-phase windings are identical. Each phase is tested against the others and compared to ensure that they are identical.
Special Surge Test of Coils (API 541 Fourth Edition Paragraph 4.3.4.2.1)

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For motors that are tested on a dynamometer, the vibration that is recorded may not meet the requirement provided by API 541 fourth edition because of the setup and nonisolated equipment around the testing area. These points require an alternate method that must be approved by the purchaser for evaluating the performance and reliability of the motor. The hot-to-cold vibration change provides information about the vibration characteristics of the motor from a hot condition to a cold condition. This method takes a hot uncoupled point of vibration and is divided by a cold uncoupled point of vibration at the same location to determine the change in vibration due to heating. This ratio is then multiplied by the no-load vibration recorded during the no-load testing on the seismic mass. This is called the responsive amplification factor and must meet the vibration criteria provided by API 541 fourth edition. Also new to API 541 fourth edition, the vector change between the cold uncoupled value and the hot uncoupled value must not exceed 0.6 mil on the shaft and 0.05 in per second (ips) on the bracket. This vector change is only evaluated on the filtered 1X vibration. Appendix E shows examples of the method to determine the resultant vector change and acceptability criteria. If the motor does not pass the

This test is recommended for windings rated 6,600 V and above. When specified, two extra coils are processed along with the complete wound stator windings for testing. The test for one coil consists of three successive applications of an impulse voltage with a 1.2-ls rise time, a 50-ls tail time and a crest value of 5 PU. This impulse voltage is applied to both terminals of the coil conductor while the conducting surfaces of the simulated slot portions of the coil are connected to ground. The remaining coil receives a test of the turn insulation with no less than three voltage impulses within 1 min applied between the coil terminations. The impulse voltage will have a rise time of 0.10.2 ls with voltage values of 2.0, 3.5, and 5.0 PU. The crest value is gradually increased until the point of insulation failure is reached. If a failure occurs at less than 5 PU, the cause of failure needs to be understood to determine the impact to the stator. A special warranty agreement between the purchaser and the vendor may need to be reached.
Power Factor Tip-Up Test (API 541 Fourth Edition Paragraph 4.3.4.3)

This test is recommended for motors that operate at 6,600 V and above, which provides a baseline for later

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maintenance tests to detect corona discharge within the insulation system. This test may also be performed on specified sacrificial coils for development testing, but an acceptance criterion needs to be agreed upon between the user and the supplier if this test is going to be performed on a purchasers motor. The relative difference (tip-up) may be used as an acceptance or baseline parameter. The power factor tip-up test is conducted across a voltage range less than to greater than the rated nameplate voltage to determine the general condition of the winding insulation. The difference in power factors between the measurements made at the lowest test voltage and at operating line-to ground voltage is referred to as the power factor tip-up. The test results are plotted for each motor, and the percent deviation is calculated. When multiple motors of the same design are tested and compared, the test values should be similar. Any motor that deviates significantly from the other motors should be investigated further for any potential winding or insulation problems. It is recommended that this test is performed on a routine basis and trend the test results. By trending the test results, the users can determine when and if an outage is required to overhaul the machine. In general, the lower the tip-up value, the better the quality of the insulation.
Sealed Winding Conformance Test (API 541 Fourth Edition Paragraph 4.3.4.4)

is the coil bracing uniform? (the bracer rope should overlap to provide the most mechanical integrity) n are the lead connections secured for some length within the coil head before exiting? n are the leads labeled in such a way that the manufacturer can keep track of which lead is through the VPI process? n are RTDs properly located between top and bottom coils?
n

Complete Test (API 541 Fourth Edition Paragraph 4.3.5.1)

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This test may be applied to critical, special-purpose motors that have windings that will be exposed to weather or wash-down. This test involves submerging the motor winding or spraying it with a wetting solution to verify that the winding is sealed as defined in NEMA Part 20. Results are obtained by measuring and recording the insulation resistance of the dry stator using a 500-V dc standard megger. However, many users want a fullvoltage, high-potential test. Next, the stator core is wetted either by immersion in a tank of wetting agent or by spraying the core using a wetting agent to thoroughly wet all surfaces. After wetting the stator core, another insulation resistance measurement is taken using a 500-V dc megger. The value of resistance at the initial application of voltage at 1 min and at 10 min is recorded. If the windings fail this test, the stator may be put through another vacuum pressure impregnation (VPI) cycle and retested. If the windings fail to pass this test after a third attempt, a new stator winding may be manufactured at the purchasers option.
Stator Inspection Prior to VPI (API 541 Fourth Edition Paragraph 4.3.4.5)

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This is a physical inspection of the wound stator before the winding is put through the VPI process. Purchasers of motors that are critical, unspared machines or have voltage ratings 6,600 V and above should select this physical inspection. The inspection should be witnessed when specified on the data sheets. Inspection points to consider are as follows: n is the entire winding assembly checked? n is it clean and free of contamination? n is it free of any visible damage? n does it look uniform and consistent? n are the coil heads uniformly taped with adequate tension?

This test is common for large or critical service machines and two-pole units. There are several methods for an API 541 fourth edition complete test to be specified and completed that will show the motor performance and durability. In IEEE Standard 112 [2], there are several methods for performing this test, but the most common are Method B (dynamometer testing) and Method F (equivalent circuit calculation). Method B testing requires that the motor be mounted on a dynamometer while Method F testing can be performed without any load applied to the motor. If the motor manufacturers facilities do not allow for Method B testing, Method F is an alternate method. Another part of the complete test is to determine the locked rotor power factor. This value is obtained by blocking the motor shaft such that it cannot rotate and recording motor voltage, current, and kilowatts in the locked rotor condition. With these data, the locked rotor power factor can be calculated and provided in the test report. The methods that are provided in IEEE Standard 112, Method B [2] allow for the full-load current and slip to be measured in a running condition. The other methods allow for assumptions and calculated values to determine the current and slip. Within IEEE Standard 112 [2], there are different methods of measuring locked rotor, accelerating and breakdown torque, and current. These values are measured using one of the various methods supported in the specification. Additional data can then be calculated depending on the IEEE test method selected by the motor manufacturer due to the test facilitys capabilities. The test can be completed at reduced voltage to minimize the test facilitys requirements, and calculations can be used to determine the motors torque and current versus speed characteristics at rated voltage. Another part of the API 541 fourth edition complete motor test is the heat run testing that is performed at rated service factor for a minimum of 4 h or until the bearing and winding temperatures stabilize per IEEE Standard 112 [2] (1 C or less change in temperature over a 30-min period). The dual-frequency testing as described in IEEE Standard 112 [2] details how the motor is heated in the absence of any mechanical loading at the shaft extension. The method used to bring the motor up to operating temperature is generally at the discretion of the motor manufacturer and/or test facility. The test involves one power source that has a low-voltage auxiliary power source of a different frequency superimposed on it. The auxiliary power supply is usually 10 Hz below the frequency of the main power supply and has the same rotation. The auxiliary voltage is adjusted so that the motor operates at rated current. The dual frequency heats the rotor very quickly, simulating the affect of running the motor at full mechanical load.

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Noise Test (API 541 Fourth Edition Paragraph 4.3.5.1.1.g)

The noise test is conducted in accordance with NEMA MG-1 Part 9 with the motor operating at no load, full voltage, rated frequency, and sinusoidal power. NEMA MG-1 Part 9 describes measuring noise in terms of sound power levels, but many motor manufacturers and specifications require measurements recorded in sound pressure levels. Sound power is the rate of energy transfer in a medium and is neither room nor distance dependent and belongs strictly to the sound source. Sound pressure is the force of sound on a surface area perpendicular to the direction of the sound. Sound pressure is basically the change in the local ambient pressure due to the passage of a sound wave. The sound pressure level can be directly calculated from the sound power level per the following:   2prd2 Lp LWA 10 log10 , (2) So where Lp is the average sound pressure level in a free-field over a reflective plane on a hemispherical surface at 1 m distance from the motor in decibels, Lwa is the sound power level in decibels, rd 1.0 m 0.5 times the maximum linear dimension of the motor in meters, and So 1.0 m2. Noise levels are typically specified as 85 dBA at 3 ft (1 m) under no-load conditions however a purchaser can chose lower levels on the data sheet. Noise levels less than 85 dBA should be discussed with the motor vendor to determine impact on the design.
DC High Potential Test (API 541 Fourth Edition Paragraph 4.3.5.1.2)

because of test stand limitations; hence, the following tests are considered equivalent tests to the actual load test. The dual-frequency testing was discussed in the Complete Test section and describes the method of testing to create the heat into the rotating assembly. In the forward stall short-circuit method, the motor being tested is driven at rated speed and rotation by an auxiliary drive motor. The terminals of the motor under test are connected to a reduced voltage fixed frequency supply with normal rotation. Generally, the supply frequency is 2025% less than the machine rated (nameplate) frequency. The auxiliary drive motor should have a power rating of at least 10% of the motor under test. With the auxiliary drive motor driving the test motor at rated speed, the voltage at the motor terminals is adjusted to rated current. The machine under test is then operating as an induction generator with a slip of approximately 25%. Because the reduced voltage on the machine produces lower than normal stator iron losses, the test is repeated with two no-load temperature tests at rated frequency. The first noload test is at the motors of rated voltage. The second test is run at the voltage used during the forward stall test. The difference between the stator temperature rises in these two tests is added to the temperature rise measured during the forward stall test. The resultant temperature rise is used as the total temperature rise. Several additional tests may be required until the calculated total temperature rise is achieved.
Unbalance Response Test (API 541 Fourth Edition Paragraph 4.3.5.3)

The dc high-potential test (sometimes referred to as the step voltage test) measures the dielectric strength of the insulation to some predetermined level. This test may aid in predicting the condition of the stator windings. It may also allow approximate prediction of the insulation breakdown voltage. During the dc high-potential test, the voltage is increased in a step function to the maximum voltage in Table 2. As the voltage is increased in steps, a microammeter is used to observe the leakage current while recording voltages and leakage currents at each step. The dc highpotential test is a when specified test that should only be specified if the end user is planning to conduct a dc test in the field for trending purposes. The recommended maximum test dc voltage is listed in the Table 2.
Rated Rotor Temperature Test (API 541 Fourth Edition Paragraph 4.3.5.2)

The unbalanced response test verifies that the motor does not generate excessive vibration when it passes through its first resonant speed or critical speed. The test also finds or verifies the location of the resonant speed. This test is recommended for all flexible shaft motors typically two-pole motors of 800 hp and larger and four-pole motors of 5,000 hp and larger. For rigid shaft motors, this testing is important to locate and verify that the critical speed is above the 15% separation margin that is required by API 541 fourth edition. This test is also important for motors intended to operate on variable frequency drives or those with starting capabilities that exceed API 541 fourth edition paragraph 2.2.4.1.
TABLE 2. DC HIGH-POTENTIAL TEST VOLTAGE LEVELS FROM API 541. Motors Rated Voltage (kV) E 2.3 2.4 4.0 4.16 6.6 6.9 13.2 13.8 DC High-Potential Test Voltage (kV) (2E 1)(0.75)(1.75) 7.4 7.6 11.8 12.2 18.6 19.4 36.0 37.5

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Specify this test if the motor is not going to have a complete API test, but it is still important to know that the rotor is thermally stable. There are three methods available to conduct this test: 1) loading the machine with a dynamometer or similarly calibrated load 2) the dual frequency method 3) the forward stall short-circuit method. Loading the test motor with a dynamometer until thermal stability has been achieved is the recommended method to demonstrate that the rotor has reached its operating temperature. This method is not always practical

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When flexible shaft motors are operated on an adjustablespeed drive below their base speed, care must be taken to ensure that the speed range does not include the critical speed. To avoid this, the drive is typically set to block out or skip continuous operation at the speed range from 15% below to 15% above critical speed. The same concerns exist when using a variable frequency drive to operate a rigid shaft motor above its base speed possibly encroaching on the first lateral critical. The unbalance response test is conducted by attaching a known unbalance weight to both ends of the rotating assembly with the weights in phase to excite the first resonant frequency. Rotating one weight 180 out of phase will excite higher-order resonant frequencies. The minimum unbalance weight is determined by taking the allowable residual unbalance weight (Umax) of 4 W/N and multiplying that amount by four. Therefore, the unbalance response weight is equal to 4 Umax. To perform the test, an adjustable-frequency drive is set up to run the motor at 120% of rated speed and then permitted to coast to rest. During this test, the shaft vibration relative to the bearing housing will be plotted against speed. The shaft displacement value for motors with a defined separation margin should fulfill (3) or 55% of the minimum design shaft-to-bearing and seal diametric running clearances, whichever is smaller. r 12,000 , (3) Ds 1:5 N where Ds is the shaft displacement, in mils peak to peak, and N is the operating speed nearest the resonant speed of concern (revolutions per minute). Consider the following example in which the operating speed is 3,600 rev/min and shaft-to-bearing clearance is 6.00 mil. For this example, the shaft displacement Ds 2.74 mil. From a shaft-to-bearing clearance approach the allowable shaft displacement would equal 3.33 mil. The smaller value is then the maximum shaft displacement the motor is allowed to experience outside of the resonant frequency zone. Additional limits for the shaft displacement at any speed outside the operating speed range or separationmargin limits shall not exceed 80% of the minimum design shaft-to-bearing diametric running clearance. Using 6.00 mil as the shaft-to-bearing diametric running clearance provides an allowable shaft displacement level of 4.80 mil while going through the resonant frequency. The unbalance response test should provide a result showing the first resonant speed is at least 15% above or below the motors operating speed. When a motor does not comply with the 15% separation margin, a well-damped resonance (response) must be demonstrated. To do this, run the motor to 120% of its rated speed with the unbalance weights attached and then allow the motor to coast to rest. The shaft displacement over the entire speed range, from 0% to 120%, shall not exceed the following value: r 12,000 Ds 1:5 , (4) Nmax where Ds is the shaft displacement, in mils peak to peak, and Nmax is the maximum rated speed in revolutions per minute. Also, when selected on the data sheets, the coupling must be mounted for the unbalance response testing. This item

can be selected on the data sheets to specify the proper testing along with the selection for the unbalance response test.
Housing Natural Frequency Test (API 541 Fourth Edition Paragraph 4.3.5.4)

This test is typically specified for the first motor manufactured of a certain frame size or a uniquely designed motor. The risk of not requiring this test is low for a previously established design due to the low bearing housing vibration limits required by API 541 fourth edition. The test results are obtained using an fast Fourier transform (FFT) analyzer. Impact testing is performed by using a calibrated hammer to impact the bearing housing while an accelerometer measures the response from the impact. The bracket response is acquired in the horizontal, vertical, and axial directions with the impact being made in the same direction as the response being measured. To eliminate the interaction between the bearing housings, the rotor shall be turned at a slow roll speed (200300 rev/ min). The separation margin between the location of the resonant frequency and the operating speed must be at least 20%. A 15% separation margin also applies to two times operating speed and also one and two times line frequencies. A significant resonance is defined as a peak that lies within 6 dB in amplitude of the fundamental bearing housing resonance. A bracket response test with a natural frequency location at 164 Hz is well above the operating speed of 60 Hz. Also, it provides more than a 15% separation margin from the 1X and 2X running speeds and line components. Conclusions This article describes the types of testing for specific motors per API 541 fourth edition. This article will help specify the proper motor testing for a API 541 fourth edition motor. Also, it serves as a quick reference guide for API 541 fourth edition paragraphs. References
[1] M. J. Costello, Shaft voltages and rotating machinery, IEEE Trans. Ind. Applicat., vol. 29, no. 2, pp. 419426, Mar./Apr. 1993. [2] Standard Test Procedures for Polyphase Induction Motors and Generators, IEEE Standard 112. [3] Motors and Generators, NEMA MG-1. [4] Form Wound Squirrel Cage Induction Motors500 Horsepower and Larger, API Standard 541, fourth ed. [5] IEEE Guide for Testing Turn-to-Turn Insulation on Form-Wound Stator Coils for Alternating-Current Rotating Electric Machines, IEEE Standard 522. [6] EASA Electrical Engineering Handbook, Electrical Apparatus Service Association, Inc., St. Louis, MO, 1997. [7] IEEE Recommended Practice for Testing Insulation Resistance of Rotating Machinery, IEEE Standard 43. [8] D. Synder, How to make bearings last in electric motors, Mach. Design, Apr. 2006. [9] H. Penrose, Keeping up resistance, Uptime Mag., Feb. 2007.

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Timothy Wayne Paschall (wpaschall@baldor.com) and Bryan K. Oakes are with Baldor Electric Company in Kings Mountain, North Carolina. Gary Donner retired from Shell Oil Products. Paschall is a Member of the IEEE. Oakes is a Senior Member of the IEEE. Donner is a Fellow of the IEEE. This article first appeared as Navigating the Test Requirements of API 541 Fourth Edition at the 2007 Petroleum and Chemical Industry Conference.

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