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Field and shop motor testing

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Harcharan Diocee
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17 views

Field and shop motor testing

Uploaded by

Harcharan Diocee
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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AUG 2024 by Harcharan Diocee

Field and In shop testing of motor or submersible pump windings

Motors can stop working causing plant process shutdown affecting the entire plant productivity.

Most electricians perform a “megger” test on the winding to determine if it’s low to ground.
Megger testing is only one of few tests that are necessary to determine root cause of motor
windings. Additional tests are outlined below to provide a better analysis

To determine motor faults the following should be followed:

Test 1: Megger test. Line to ground

1. Spin shaft by hand and listen to bearing or rubbing noise.


Push and pull the shaft to see if there is excessive end play.
Lift the shaft up and down to check for any radial movement which could cause rotor to
stator rubbing when energized.
2. Ground test: aka Megger test. What is this test?
The windings in a motor are inserted in stator slots which are lined with insulation paper
called nomex. The magnet wire is coated with enamel ie polyamide which provides turn to
turn insulation, and coils are inserted in the “insulated slot”

The ‘ground test’ measures the


resistance of the insulation paper
between the copper conductors
of the coils to motor frame.

3. Open junction box cover and split open the power cables to winding leads if feasible. On a
submersible pump in the water, perform the test at end of the power cable entering the
control panel and motor/pump magnetic starter OR fused disconnect switch.
- Shut off and lock-out the incoming power into panel
- Use jumper grounding cables to ground out going wiring to panel ground to discharge
any capacitive charge in the winding or electronic devices.
- Remove the cables at contactor to motor.
- If conditions are safe the motor cables can stay on the disconnect device.
4. Perform megger test using a ground insulation tester: aka Megger.
Insulation resistance testers have voltage ranges: 300V, 500V ,750V, or 1000 volts.
Motors ≤600Volts apply 500V or as suggested by manufacturer.
Motors ≥600Volts apply 1000V

-Connect the megger RED wire to the winding Leads in J Box OR starter panel and BLACK
wire to the ground terminal or motor metal housing. Press “ON” button and hold for 1 min.
-Record the resistance reading to ground.
-Record motor/winding temperature and humidity 9f available, at time of test
Factors affecting “low resistance reading”
Moisture, water ingress, condensation, or other contamination or age, can ‘weaken’ the
insulation properties.

NOTE: A low resistance reading DOES NOT mean the winding is shorted or burnt out.
SAFETY DUE TO HIGH VOLTAGES DO NOT TOUCH THE METER LEADS OR MOTOR
FRAME DURING MEGGER TEST

After megger testing a winding, use a “jumper wire with alligator clips to connect the
winding lead wires to motor frame or ground wire for at least 1 min.

Test 2: Micro ohmeter resistance test line to line. A multimeter may not accurately read <1 Ω

Connect meter leads to any two lead wires of


winding and record the resistance
Swap leads with the other phase and repeat test.
Record readings in milli or milli ohms.
L1-L2; L2-L3: L1-L3: ALL
readings should be within 3%

If readings differ the windings may be shorted


phase or turn to turn short. Further investigation
is required. NOTE With a shorted coil the
insulation and megger may be satisfactory
Test 3: Impedence (Inductance) test: using an inductance meter

Connect meter leads to any two


lead wires of winding and record
the resistance
Swap leads with the other phase
and repeat test. Record readings in
mH or H (H is henry)
L1-L2; L2-L3: L1-L3:
ALL readings should be within 3-5%
If readings differ there may be
shorted phase or turn to turn short.
Further investigation is required.
NOTE With a shorted coil the
insulation and megger may be
satisfactory.

IF an impedence meter is not available:


Power supply test: Single phase reduced power
Apply approximately 10 to 20% of Name plate voltage 1ph voltage Line to Line and record
current draw (not to exceed FLA on nameplate)
L1-L2; L2-L3: L1-L3: ALL readings should be within 1%

Power supply test: three phase reduced power


Apply approximately 10 to 20% of Name plate voltage Line to Line and record current draw
(not to exceed FLA on nameplate)
L1-L2; L2-L3: L1-L3: ALL readings should be within 1%

SUMMARY:
If after any of the above tests fails or is not satisfactory the motor or pump has to be pulled
out of service.

PUMP: Remove from water and disconnect cable from winding leads.
Megger test the cable by it self between the 3 power wires and one ground wire.
Megger test the winding leads to confirm if the motor is faulty or cable is faulty.

Once all above tests are completed the removed motor/pump can be sent to a rewind
shop, to be dismantled and further evaluated

There are other tests but require sophisticated equipment


- Surge comparison tester
- Hipot tester
- Power analyzer/scope

HSD: copyright BSD Services Inc

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