HT MOTORS TESTING.

INTRODUCTION
We are familiar with different types of motors for different purposes. Among them HT Motors plays a vital role in many industrial applications. For such motors before running & make use, it should be tested perfectly for long reliable running and operation.

IS TESTING NECSSARY?
Testing is required to know the performance, functioning, healthiness status and efficient operation of the equipment.

CLASSIFICATION OF MOTORS.
There different types of motors depending on their classifications. Those broadly divided as, 1.) A.C. Motors. 2.) D.C. Motors.

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..,

In further, these A.C. Motors are classified as , 1) Asynchronous Motors. 2) Synchronous Motors. Depending on the type of power supply required it is divided as, 1) 3- Phase and 2) 1- Phase

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Depending on operating voltage they are classified as, 1.) HIGH TENSION (H.T.)
HIGH VOLTAGE.
or

2.) LOW TENSION (L.T.)

LOW VOLTAGE.

or

H.T. MOTOR TESTING.

There are mainly two different types of testing are needed for any H.T. motor. 1) PHYSICAL TESTING. 2) ELECTRICAL TESTINGS.

PHYSICAL TESTINGS.
In physical inspection of the motor the following should be considered 1) Tightness of terminals. 2) Damages. 3) Grouting (if it is installed in the working area or field). 4) Earthing of motor (minimum at two point) 5) Dynamic balancing test of rotor 6) Visual inspections

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7) Rotor Alignment. 8) Air gap for flux. 9) Freeness of rotor 10) Tightness of foundation & all bolts of housing The following are also under physical testing but can be observed at the time of trail running condition only. i. Vibration. ii. Temperature Rise. iii. Noise level.

1) Tightness
Terminals should be tightened else local currents will increase.

2) Damages
Any physical damages (like breakage) should be taken care immediately.

3) Grouting.
Alignment on the base frame and grouting should be done well else vibration will increase with respect to the load in the running operation of the motor.

Visual Inspections.
Visual checking like painting rusting should be observed if required painting should be done to the ferrous metal parts of yoke only

5) Rotor Alignment.
Rotor should be aligned in the stator properly in order to make the use of full capacity of the rotor.

6) Air Gap Checking.

Air Gap between the Stator and the Rotor should be uniform and it should be measured.

Vibration.
Vibration should be measured with the help of vibrometer at different load conditions (including no load and over loads) during the running of the motor in all the three coordinate directions of horizontal, vertical, and axial.

Temperature Rise.
Temperature should be taken after the motor have a thermal steady state by using RTDs by measuring at different points around the motor.

Noise Level.
Noise level should be measured in the running of the motor by using Sound level meter.

ELECTRICAL TESTINGS.
There are several Electrical Tests that can be performed for H.T. Motors. Among them the following can be performed at the site itself. Insulation Resistance. Winding Resistance. A.C. withstand Test. D.C. withstand Test. Bearing Insulation Resistance Test. Polarity of Stator Impulse withstand test Polarization index test Temperature rise test Tan delta test

Insulation Resistance.
Measure the winding insulation resistance and absorption factor by using 2500V electrical megger and its value should be greater than 1 M.

Winding Resistance.
D.C. Winding Resistance of the motor phase winding should be measured with DC double bridge method.

A.C. withstand Test.

Use Testing Transformer of 220V/10KvV induce high A.C. voltage than its rated nearly (2 times the rated Voltage +1) for 1 minute and check the withstand capacity of the motor.

D.C. withstand Test.

Induce high D.C. Voltage exactly 2.5 times the rated Voltage and for 1 minute and check any abnormality is there and try to find the leakage current in all the three phases and it is preferable to have less than 20uA.

Bearing Insulation Resistance Test.

Bearing of the H.T. motor should be an insulator. so it is to check the resistance of the bearing by using the Electrical Megger. In General the resistance value of the insulation shall not be less than 0.5 M.

Polarity of Stator.
Check the polarity of the stator windings with each other by providing small voltage to Rphase and check polarity for the remaining phases, by D.C. induction Method. After all these testings are completed then conduct load test.

Shaft Currents & Voltages.

Shaft currents & Voltages may be produced in a machine due to various factors. The machine run at no load and at rated supply voltage and frequency. A rectifier type moving coil voltmeter of full scale deflection of 5 volts should be connected across the ends of the shaft of the machine by means of solid copper prods firmly held in the shaft centers.

Load Testing.
After all the pre running tests are completed the motor is tested with the load tests for knowing performance characteristics and efficiency of the motor. The following are the types of load tests. i. No Load Test (open circuit test). ii. Load Test. iii. Blocked Rotor Test (short circuit test).

Load Test.
I. De-Coupled load Test.
At the stage of No load and pump decoupled motor will be trail runned and current, voltage, frequency, power etc will be measured in ordered to find the no load core losses, friction and windage losses etc. Load test will be conducted and by increasing the load at different loads and current , speed , power, power factor and torque are measured.

II. Load Test.

Blocked Rotor Test.

Blocked rotor test is also know as short circuit test by blocking the rotor and inducing the voltage and measuring the starting torque, current, power factor and power finally finding the short circuit characteristics and short circuit losses of the motor to finding the efficiency of the motor.

NAME

KW
2000 1000 5400 710

CURRENT
199.2 100.4 532 72.5

RPM
1485 1490 1493 1491

P.F(cos)
0.921 0.914 0.913 0.913

PA FAN MOTOR CEP MOTOR BOILER FEED PUMP MOTOR FD FAN MOTOR

ID FAN MOTOR
MILL MOTOR

2800
710 1450 215 410 250 355

309
78 181.8 25 44.5 26.5 69

747
992 424 987 1486 1490 1480

0.821
0.84 0.87 0.88 0.86 0.89 0.89

CW MOTOR
ACW

CCCW MOTOR
IA COMP. MOTOR RIVER WATER INTAKE PUMP MOTOR CRUSHER MOTOR

550

70

742

0.73

THANKS.