Electric Motor Testing… indication.

A connection that is gradually

the Missing Link of

working loose, for example, will show an
increasing unbalance over time.

Condition Monitoring?
Meg-ohm test: will show if the motor
has a dead short to earth, is wet or
contaminated, and can perform a
Polarisation test (PI test). A meg-ohm test
cannot show if a motor is in good condition,
Michael Herring, EU Product Manager, Baker Instruments
as it does not test the entire insulation
system.
PI Test: is a 10 minute test, which
It is argued that condition monitoring of electric motors should incorporates the 1 minute meg-ohm
Abstract

test. At the end of the test, the 10 minute

involve not only testing for such things as bearing failure - via meg-ohm value is divided by the one
vibration analysis, oil analysis and so forth – but also a structured minute value, and a ratio of 2 or more is
typically deemed as acceptable. Some
testing regime for electrical faults and the monitoring of motor insulation classes accept a lower PI ratio,
efficiency. Energy costs are a major portion of any plant or facility’s as do some engineers, depending on the
location/application of their motors. The PI
operating expenditures and motors consume a very large part of
test is generally performed on high voltage
those expenses. Correct monitoring of motor performance, and motors, and is used to measure the ability
making the necessary adjustments, will improve reliability, extend the of an insulator to polarize.

life of the motor and reduce the overall operating cost of the facility. DC Step Voltage Test: is typically
performed at twice line voltage plus 1000
volts. The voltage is increased in a series
of steps, ideally five steps or more, and the

F
or many engineers, condition
monitoring of electric motors is
seen as the use of vibration analysis,
thermography, laser alignment and oil
analysis. All too often, electrical testing as
part of a condition monitoring regime is
deemed as unnecessary. However, studies
show that, after bearing failure, electrical
faults are the most common mode of motor
failure, so in addition, a structured electrical
testing regime is vital for ensuring plant
reliability. The meg-ohm test has long been
the tool of choice for most engineers, and
this simple test is often the only electrical
test performed on a motor. However, while
the meg-ohm test has a valid role to play,
it is simply not capable of detecting all the
likely faults within a motor’s winding.
Modern test equipment utilises PC control
to provide automatic testing and fault
diagnosis, thus removing the onus on
the operator to interpret the results. The
equipment has the ability to detect micro
arcs, and to stop the test automatically.
Database software allows assets to be
saved with all test results, so that a trend
can be built up over time, ideally from when
the motor is new.
Automated testing also helps remove
operator error, inconsistency created
by different operators applying different
parameters and the possibility of the
operator applying over-voltage to the
motor. The latest testers combine all
static electrical tests within one portable
device, which also have the ability to create
professional test reports.
Static or insulation testing: is performed leakage current is plotted. Good insulation
with the motor disconnected from the to earth will show a linear plot (see Figure
power supply. It is typically performed from 1), whereas a non-linear plot (see Figure 2)
the motor control cabinet, and should be would suggest an insulation weakness (or
carried out in a specific test sequence: contamination) at that voltage where the
leakage current suddenly increased. The
Winding resistance test: will highlight step voltage test provides a great deal more
dead shorts, loose connections and open information than the basic DC hipot test.
circuits. Such tests must be performed
The DC Hipot test: simply applies a
with accurate equipment, which is
voltage, measures leakage current and
capable of measuring down to 0.001
calculates meg-ohms. If the meg-ohms
ohm. It is extremely important to correct
are higher than the accepted minimum
the resistance values to a constant
value, the motor passes. Even if there is an
temperature, typically 20 degrees Celsius.
area of damaged insulation which causes
The motor temperature must be measured
a lower reading of meg-ohms, as long
as accurately as possible, and where
as that value is higher than the minimum
possible, the copper temperature should
accepted value, it will still pass.
be used. A motor that has been recently
operating is very unlikely to be at ambient
temperature, so
the use of ambient
temperatures
should be avoided.
Upon completion
of the test, the
percentage
unbalance between
the phase-to-
phase readings
is calculated
[Unbalance =
(maximum –
minimum)/average,
and expressed as
a percentage]. An
unbalance of less
than 1% is typical
for a good winding,
Figure 1 Linear leakage current plot
although trending of this gives the best
Fig. 1 – Linear leakage current plot

maintenance & asset management vol 26 no 6 | ME | Nov/Dec 2011 | 41

 Figure 3 shows the and we can also see this in Figure 3, when
result of a surge test the waveform shown in red also shifted
on a 415 volt motor. to the left. Very early signs of turn-to-turn
The motor had been insulation weakness can be observed in
subjected to severe the pulse-to-pulse graph, even though the
overheating, but surge waveforms may show close balance.
still ran normally. A
meg-ohm test at 500 WHY HIGH VOLTAGE
volts passed with TESTING ?
1,438 meg-ohms. The
surge test failed at A common question relates to the voltage
1,590 volts on Phase 1. levels that should be applied. Why should
Phases 2 and 3 both a 415 volt motor be subjected to a 2000
passed at the full test volt test? The reason relates to the
Figure 2 Non-linear leakage current plot voltage of 2000 volts. All three waveforms high voltage spikes that motors see on
should be balanced to each other. start-up and shut-down. 415 volt motors,

Surge test: This final test is used to verify

the turn-to-turn, coil-to-coil and phase-to-
phase insulation condition, and is typically
performed at twice line voltage plus 1000
volts. It can detect weak insulation, dead
shorts, loose connections, and unbalances
caused by incorrect winding. It works by
injecting high voltage pulses into each
phase, creating a potential difference
between one turn and the next. The
resultant sine waves from each phase
should match one another.
Paschen’s law states that in order to
draw an arc between two conductors, a
potential difference of at least 350 volts
is required. When motors start and stop,
high voltage spikes can be generated,
and these spikes are what damage the
insulation over time, along with heat, attack Figure 4 Turn-to-turn arc detected
from oil, ingestion of chemicals, and also
movement of the copper wires due to the Figure 4 shows the point at which Phase particularly those started direct-on-line,
magnetic forces on start-up. 1 failed. The pulse-to-pulse graph plots will regularly see voltage spikes of up to
all pulses that are injected into the three 2000 volts. Therefore, to be able to see
Of all the tests described, the surge test phases and the resultant plot should insulation weakness in advance of failure,
is the only method of detecting weak turn show close balance between the three testing needs to be carried out at similar
insulation. Studies have shown that 80% of phases. The spike shown in red is the levels. International standards apply to
electrical failures originate as a turn-to-turn result of an arc within Phase 1. When the all these tests, including those of the IEC,
weakness, so in order to detect such faults arc occurred, it caused the inductance of IEEE, NEMA and EASA.
prior to motor failure, surge testing must be the phase winding to change momentarily,
performed.
DYNAMIC MOTOR TESTING
A more recent addition to electrical testing
technologies, this involves measuring the
voltage and current of the motor’s three
phases, while the motor is operating in its
normal environment, and calculating a host
of information relating to the power supply,
the motor, and the load. Both electrical and
mechanical issues can be identified.
Power quality values, including voltage
level, unbalance and distortion are
determined and compared to industry
standards. Poor power quality can lead to
overheating within motors, and since heat
is the biggest enemy of insulation, power
quality problems should be identified and
corrected where possible.
Figure 3 Failed surge test

42 | Nov/Dec 2011 | ME | maintenance & asset management vol 26 no 6

 Electric Motor Testing…the Missing Link of Condition Monitoring?

Figure 6 shows 28 seconds of

instantaneous torque being demanded of
a 2.2MW motor at a cement factory. With
this application, one would not expect
these large, rhythmical peaks of torque.
These peaks highlighted a mechanical
problem with the driven gear.
Transient analysis: plots the rms voltage
and current against time, while the motor
is starting, and also plots the torque profile
during that time. Monitoring all three
phases of voltage and current, plus torque,
allows maintenance engineers to separate
power, motor and load issues. Figure 7
shows the voltage and current plotted
against time during the start-up of a 132kw
motor on a soft-start.
In summary, dynamic electrical testing
can be used to identify a wide range of
electrical and mechanical issues simply
by measuring the 3-phase voltages and
currents at the motor control cabinet. It
Figure 5 Graph indicating bad rotor bar can also provide a comparison with other
technologies, such as vibration analysis. It
Current level and unbalance: are used to can be performed on submersible pumps
determine overall electrical health, and are and motors in restricted areas, simply by
used to identify overloading, connection having access to the switch room.
problems, iron saturation and incorrectly
wound motors.
Spectrum analysis: allows the condition
of the rotor bars to be determined (see
Figure 5), as well as showing the voltage
and current relationship to frequency.
Saturation problems, inverter issues,
as well as mechanical detects, can be
detected.
Torque: can now also be used to find a
host of problems including, among others,
transient overloading, pump cavitation,
mechanical imbalances and bearing faults.

Figure 7 Transient analysis

The author
Michael Herring (michael.herring@skf.
com) is EU product manager for the Baker
Instruments Company, an SKF Group
Company. He works closely with Whitelegg
Machines, the UK and Ireland sales and
Figure 6 Torque ripple graph service engineers for Baker Testers.

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