IEEE 115 Measure Shaft Voltage

Bearing Insulation Testing
in
Rotating Machinery
by
Paul I. Nippes, PE
and Beth Galano
Magnetic Products and Services, Inc.
Holmdel, NJ 07733
”Safeguarding Machinery Worldwide “

www.gaussbusters.com
Table of Contents
The value and problems of bearing insulation are addressed.
Examples of damage are provided where bearing insulation had been shorted
out, or was ineffective.
Examples for insulating bearings and couplings are shown.
Simplified diagrams for shaft current flow are presented.
An example of un-measureable, circulating bearing current from homo-polar
magnetic flux is presented
Safety during testing is stressed.
Methods for determining the integrity of bearing insulation are provided in the
form of IEEE Standards and MPS practices for testing bearing insulation.
Insulation testing methods with the unit operating are addressed.

WHY INSULATE BEARINGS ?
First insulated to block stray currents from destroying bearings in

electric motors and generators in the early 1900’s.
Bearing insulation continues to be installed at the outboard end of
electrical machines.
expensive to install and maintain
lowers the bearing support stiffness, adding complication to design and
vibration analysis
when OE is also a drive, electrical insulation is needed, either at the
coupling, and/or at the driven equipment as well.
In recent years, simple insulation installation is proving to be
inadequate to block bearing currents where electronic switching is
prevalent.
Two vital considerations:
resistance of the insulation
it’s capacitive impedance

Elementary representation of a motor driving a Load
DRIVEN-LOAD: PUMP, ELECTRIC MOTOR, SYNCHRONOUS,

COMPRESSOR, ETC. INDUCTION OR DIRECT CURRENT
ROTOR
OI L FILM
BEARING
STATOR ELECTRICAL INSULATION
Elementary diagram for considering shaft currents in typical motor - load arrangement

Elementary diagram for considering shaft currents in typical turbine - generator arrangement

“One method of insulating
bracket-type machine to
prevent flow of shaft
currents” in article “Bearing
Currents --- Their Origin and
Prevention” by C. T. Pearce,
of Westinghouse Electric,
1927

Modern method for insulating
bracket type machines in article
“Shaft Voltages – Shaft/Earth
Voltages – Bearing Currents”
Article “AR 170-220” by
Siemens Field Services and
Workshop Operations 04/1991

Modern open method to insulate pedestal bearings from article “Insulating
Rotating Machinery Against Stray Electrical Currents” by Michael M. Calistrat,
Paul I. Nippes and Ned Zeman, Preventative Maintenance Technology National
Conference -1997.

Modern hidden method to insulate pedestal bearings from article “Insulating Rotating Machinery
Against Stray Electrical Currents” by Michael M. Calistrat, Paul I. Nippes and Ned Zeman,
Preventative Maintenance Technology National Conference -1997.

Four different methods to insulate shaft couplings from article “Insulating Rotating Machinery Against Stray
Electrical Currents” by Michael M. Calistrat, Paul I. Nippes and Ned Zeman, Preventative Maintenance
Technology National Conference -1997.

VOLTAGE & RESISTANCE MEASUREMENTS
ELEMENTARY DIAGRAM FOR STRAY SHAFT CURRENT CIRCUIT MEASUREMENTS
DRIVEN LOAD SHAFT COUPLING MOTOR SHAFT
BEARING OIL FILM

STRAY
BEARING
POWER
SOURCE
AC/DC
INSULATION
VOLTS

VOLTAGE & RESISTANCE MEASUREMENTS
ELEMENTARY DIAGRAM FOR STRAY SHAFT CURRENT CIRCUIT
MEASUREMENTS
DRIVEN LOAD SHAFT COUPLING MOTOR SHAFT
BEARING OIL FILM

STRAY
BEARING
POWER
SOURCE
AC/DC
INSULATION
VOLTS
INSULATION

The actual shaft voltage circuits of a boiler feed pump installation in a large power plant
Insulation
needed
here

Boiler Feed Pump from a large Generator

ELECTRICAL CURRENT
DISCHARGE DAMAGE
PITTING, FROSTING
SPARK TRACKS

ELECTRICAL SPARK TRACKS

Example of localized circulating current due to through axial, or homopolar, magnetic flux in
the rotor, from an article “Bearing Currents --- Their Origin and Prevention” by C. T. Pearce,
of Westinghouse Electric, 1927
Measurement of current in the operating

machine is impossible.
Measurement of axial magnetic flux
difficult, if not impossible.
Corrections possible:
1) Degauss if cause is a residual
magnetism source.
2) Install a significant non-magnetic
member into the flux path.

Example of Through Magnetism generating Eddy Currents

Example of Through Magnetism generating Eddy Currents –
currents discharge at outside edges passing through the babbitt

IMPEDANCE EFFECT OF DIFFERENT FREQUENCY CURRENTS THROUGH BEARING, SEAL AND/OR COUPLING INSULATION
Of major concern is the ineffectiveness of bearing insulation when subjected to high frequency voltages and more particularly the
voltage spikes associated with electronic wave generation and switching. The exact bearing insulation impedance is difficult to
determine. A simple calculation of the resistive and capacitive components of the bearing insulation reveals a significantly lowered
capacitive impedance compared to the ideal resistive component and thus controls, along with the bearing oil film, the amount of
current through the bearing. Insulation is reduced inverse to the ratio of the frequencies. The resistive component will decrease over
time due to oil impurities and insulation deterioration over time .
Impedance vs. Frequency
1E+13
2.12E+12
1E+12
Limits of
2.12E+11 Resistance
1E+11
1E+10 l/A Ratios

0.02119
1E+09 0.042354
0.063518
1E+08 0.084682
Z (ohm ) 0.105846
1E+07 0.12701
0.148174
1E+06 0.169338
0.211667
100000
10000
1000
100
10 60 110 160 210 260 310 360
Freq (Hz)

Expanded capacitive impedance for different frequency currents through bearing, seal and/or coupling insulation
demonstrating the effect of the ratio of insulation thickness (i) to the insulation effective area (a) or a/i
Impedance vs. Frequency
300
250
l/A Ratios
0.02119
200
0.042354
Z (ohm ) 0.063518
0.084682
150 0.105846
0.12701
0.148174
0.169338
100
0.211667
50
0
0 500 1000 1500 2000 2500 3000 3500
Freq (Hz)

SAFETY FIRST WHEN MAKING SHAFT
VOLTAGE MEASUREMENTS
Wear hard hat, face shield, safety shoes.

Place voltage measuring brush onto the shaft
only after you are certain that no rotating
element, such as a keyway or bolt is in the zone
of brush contact.
Move measuring brush to the shaft very slowly
and stand to the side.

Same as IEEE 112, basically

PART I – ACCEPTANCE AND PERFORMANCE TESTING IEEE
Std 115-1995

BEARING INSULATION CONDITION BY MEASUREMENTS
Comparative evaluation of the bearing insulation is possible on electrical

machines if there is access to shaft, the bearing sleeve, its housing or pedestal.
Open access to insulated pedestals and bearing housings make it convenient

for voltmeter, ohmmeter or other reliable and safe measurements.
A disadvantage of open access is the ease for shorting around the insulation by
instrumentation, shielded cables, un-insulated bolts and dowels etc.
No access, such as completely isolated bearings, both electrically and

physically, protects from accidental shorting, and is generally safe from
insulation shorting, except for wires run internal to the isolated bearing, such
as temperature detectors.
A disadvantage of no access is the inability to make insulation measurements.

However, this can be overcome by installation of an isolated metallic separator
in the bearing insulation making a or sandwich having an insulated wire
brought out for making measurements.

AN ALTERNATE PROCEDURE TO FOLLOW:
READ AND RECORD VOLTAGE VALUES, WITH THE UNIT OPERATING USING
A HAND-HELD BRUSH AND A RELIABLE METER.
RECORD SPEED AND LOAD AND IF THERE IS SHAFT GROUNDING,
PHOTOGRAPH AND DESCRIBE THE SHAFT GROUNDING,
HOW IT IS CONNECTED ELECTRICALLY AND
WHERE IT IS LOCATED ON THE UNIT.

MPS Shaft Voltage Measurements
Measure and record the voltages, AC and DC separately if using a standard voltmeter, or
as displayed if using a VCM and/or an oscilloscope :
a) Shaft end to end voltages across the driver (motor), and then across the load,.
b) Shaft voltages combined overall end to end. Should equal the sum of voltages in a)
and indicates that the measuring brush and ground interconnections are continuous.
c) Shaft voltages to ground at the OB and IB shaft locations, First, open circuit, then
with 1k Ohm and 1 Ohm resistor in parallel across the voltmeter leads. Voltage drops
indicates: w/ 1 K Ohm = electrostatic source; w/ 1 Ohm = residual magnetic source.
d) Repeat item c) for the load shaft voltages for the OB and IB shaft locations.
e) With voltages of reasonable values in a)-c), it is expected that the highest shaft
voltage measured is across the motor/generator shaft outboard end to ground. A low
voltage indicates either low source voltage or shorting of the shaft to ground
f) If individual voltages measured in a) thru d) are basically equal to zero, voltage
measurements will not suffice to evaluate the condition of the bearing insulation and it will
be necessary to conduct the same readings using an ohmmeter, but without the patallel
resistors. A decision to do nothing at this stage may be justified because of the low
voltages measured, however this may not be a permanent situation and bearing resistance
remains unchecked. Unit shut-down measurement of the insulation may be needed
following the procedures of IEEE 115, 112 and 113.
g) To continuously track the shaft grounding current/voltage install an MPS Voltage-
Current monitor and reliable shaft grounding and voltage sending brushes.

Measuring Devices
Hand-held VCM readings Storage Oscilloscope Readings

EARLY WARNING PROVIDED BY SHAFT GROUNDING AND
VOLTAGE SENSING BRUSH SIGNALS TO THE MPS VCM

CONFIGURATION # TG
DUAL GROUNDING BRUSHES, DUAL VCM’S IN ONE BOX, DUAL VOLTAGE SENSING
DUAL SHAFT
BONDING TO LOWER BEARING CASING
GROUNDING
AND FROM THERE TO GROUND
BRUSHES
HP TURB. IP TURB. EXCITER
LP TURB. GENERATOR
SHAFT VOLTAGE SHAFT VOLTAGE

SENSING BRUSH SB # 1 SENSING BRUSH SB # 2
TAPPED RESISTORS VOLTAGE SPIKE

OR CURRENT SHUNTS AND TRANSIENTS
VCM-E/NSII
ABSORBER
EASY ACCESS
SHAFT CURRENT AND VOLTAGE
FOR ALARM
SIGNALS-OUT FOR CONTINUOUS
SETTINGS.
TRENDING AND ALARMING

Shaft Condition VCM and grounding brushes that provide early warning of problems
via monitoring shaft voltages and grounding currents
Single/Standard VCM’s Shown
VCM-E FEATURES:
1.Attaches to both an insulated shaft grounding brush for
current measurement, and to a shaft voltage sensing brush for
shaft voltage measurement.
2.Continuously monitors and outputs 4-20 ma signals for shaft
grounding currents and shaft voltages.
3.Alarms when shaft riding brushes are worn or need
adjustment.
4.Alarms on high grounding brush current or high shaft
voltage.
5.Reduces costly parts replacement.
6.Ideal for critical, large or high speed rotating machinery
requiring uninterrupted shaft grounding, while providing
reliable unit condition monitoring data.

Summary and Conclusions
¾ Consider bearing insulation employed and comparative impedance
values using the characteristic graphs previously presented
showing bearing insulation ratios of thickness to gross area (t/A)
as a function of different shaft voltage frequencies.
¾ Familiarize and follow bearing insulation testing standards per
IEEE, both for operating units and those at standstill.
¾ Routinely perform bearing tests with the unit running, per MPS’
recommendations and most importantly stress safety during
testing.
¾ Educate personnel to be “on-the-watch” for damage where the
bearing insulation had either been shorted out, or is ineffective.

LETTER OF INQUIRY ON BEARING INSULATION TESTING –PAGE 1
Mr. Nippes,
This is to request your opinion and thoughts on the following voltage measurement approach. The machine in question is a
typical large STG with double insulation at the bearing and seal on the CE of the generator. A single test lead is connected
from the metal between the insulation halves.
Thank you for the interesting e-mail. You are fortunate to have the metal member between insulation halves.
However, as you discover, inconsistent readings are confusing
Often we may have a low megger reading between the test lead and ground (or possibly indication of a short circuit). When
this condition exists we do not know for certain if both insulation halves are shorted and, if they are, if the oil film is or is not
providing adequate protection against electrical discharge and pitting. Obviously, we would not intend to operate for an
extended period of time with this condition but the question always arises concerning whether we might be experiencing
damage or not during short term operation until repairs are made. A viable and consistent test approach to make this
determination would be very helpful.
Is the unit operating when you make megger readings? What is the applied megger voltage? Megger readings may be
influenced by stray voltages on an operating unit. It is preferable to fires make voltage readings, AC and DC, or with
an MPS hand-held VCM. If there is voltage, megger or resistance readings may be inconsistent , especially if done on
the operating machine.
Have you had any experience with measuring the voltage drop between the test lead and ground and between the test lead
and the shaft as a tool to determine if one or both insulation halves are shorted?
I believe the best way to test the insulation is to connect electrically the shaft to the metal separating the insulation.
Make voltage readings from this interconnection to the lower bearing housing on the operating machine.
Next remove the interconnection insulation and measure the voltage between the metal separating the insulation and
the shaft, both AC and DC or with an MPS hand-held VCM. If a notable voltage is detected chances are that the
intervening insulation, plus the resistance of the shaft oil films, for all bearings, is high and most likely protective.
If, in the above two tests the voltage is zero, an ohmmeter or low voltage megger unit according to IEEE Testing
Standards can be utilized to measure the combined insulation resistance of the oil films. If you use a 500 V megger,
false readings can occur due to possible tracking impurities on the insulation, and in some cases, the 500 V megger will
set up a tracking path. It is preferable to use the 115V with light bulb in series as listed in IEEE 112 and 115.

LETTER OF INQUIRY ON BEARING INSULATION TESTING –PAGE 2
Have you measured current flow in the ground path to determine if random discharges across the oil film might be occurring
or is this approach only useful for a sustained current flow?
It is virtually impossible to intercept the current path for inserting a current shunt and it can be equally difficult to
encircle the current path to ground for measure bearing AC currents. Bearing through current can be diverted from
the bearing through a shaft grounding brush, however will not be equal to the through-bearing current. The brush
current to ground can be measured using a current shunt signal to an MPS voltage current monitor, or VCM,
providing both intermittent and sustained readings, alarms and 4-20ma signals.
Do you think the oil film alone (in the absence of a mechanical problem that minimized the normal clearances) would be
sufficient to prevent electrical damage for voltages in the 10 to 20 volt range even if both insulation halves were shorted?
The answer is “YES”, and even higher voltages are possible for an ideal bearing oil film. You are correct to inquire if
the oil film may have contact or conduction and this may occur at any bearing, affecting tests made on the shaft
insulation. The oil film is an excellent isolator, but over time it is seldom without either contact or impurities. Very
often bearing problems do not occur until long after initial installation. This indicates increased impurity deposits or
mechanical distortion/wear would be the cause for bearing current damage. With the many variables involved, a
simple, consistent test routine is not easy to set up. Possibilities include a logic chart based upon findings and
combinations of. A satisfactory logic chart may eventually be available.
Are there other methods or approaches that you have found to be useful?
Experience is that shaft voltages, bearing contact and impurities in the oil create conditions leading to bearing/ seal
and gear currents. Sustained current in bearings, seals etc. often come from electromagnetic asymmetries in electrical
machines or from high residual magnetism. Damage is usually rapid and severe and, in absence of a shaft-voltage
current monitor, first detection is an increase in vibration and temperature.
2005. Your inquiry is well timed since I am currently composing a presentation for EPRI for delivery at the LEMUG
session in New Haven, CT, August 15-17,


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What are some methods discussed for testing the integrity of bearing insulation?

What are some methods discussed for testing the integrity of bearing insulation?

What are some factors that can affect the resistance of bearing insulation?

What are some factors that can affect the resistance of bearing insulation?

Bearing Insulation Testing

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

First insulated to block stray currents from destroying bearings in

”Safeguarding Machinery Worldwide “

DRIVEN-LOAD: PUMP, ELECTRIC MOTOR, SYNCHRONOUS,

STATOR ELECTRICAL INSULATION

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

DRIVEN LOAD SHAFT COUPLING MOTOR SHAFT

BEARING OIL FILM

”Safeguarding Machinery Worldwide “

DRIVEN LOAD SHAFT COUPLING MOTOR SHAFT

BEARING OIL FILM

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

Measurement of current in the operating

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

1E+10 l/A Ratios

”Safeguarding Machinery Worldwide “

Impedance vs. Frequency

”Safeguarding Machinery Worldwide “

Wear hard hat, face shield, safety shoes.

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

Comparative evaluation of the bearing insulation is possible on electrical

Open access to insulated pedestals and bearing housings make it convenient

No access, such as completely isolated bearings, both electrically and

A disadvantage of no access is the inability to make insulation measurements.

”Safeguarding Machinery Worldwide “

RECORD SPEED AND LOAD AND IF THERE IS SHAFT GROUNDING,

PHOTOGRAPH AND DESCRIBE THE SHAFT GROUNDING,

HOW IT IS CONNECTED ELECTRICALLY AND

WHERE IT IS LOCATED ON THE UNIT.

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

SHAFT VOLTAGE SHAFT VOLTAGE

TAPPED RESISTORS VOLTAGE SPIKE

”Safeguarding Machinery Worldwide “

Single/Standard VCM’s Shown

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “

”Safeguarding Machinery Worldwide “