MEE Unit- III: Testing and Maintenance of rotating machines

Unit- III: Testing and Maintenance of rotating machines

3.1 Testing: Need and standards, tolerance, types: routine, type, special and supplementary tests, Methods
of testing: direct, indirect and regenerative with advantages and applications.
3.2 Induction motor testing: Routine, type and special test of single phase induction motor as per IS 7572 -
1974 (re-affirmed in 2002) and three phase induction motor as per IS029 -2010.
3.3 Alternator and synchronous motor testing: Routine, type and special test
3.4 Trouble shooting chart for single phase and three induction motor (IS 900- 1992).
3.5 Foundations: Requirements and factors affecting rotating machine foundation.
3.6 Tools/instruments: Bearing puller, filler gauge, dial indicator, spirit level, megger, earth tester, growler,
test lamps, multimeter, Spanner set, and screwdrivers
Refer standard IS 7572 - 1974 for Induction motor testing: https://law.resource.org/pub/in/bis/S05/is.7572.1974.pdf
single phase and three induction motor (IS 900- 1992). https://law.resource.org/pub/in/bis/S05/is.900.1992.pdf
synchronous motor testing https://law.resource.org/pub/in/bis/S05/is.7132.1973.pdf

Electrical test is an evaluation of the parametric, functional, or timing performance of a component

when electrical power is applied. Parametric tests typically involve measurements of current or
voltage.
Tolerance is the permissible limit or limits of variation. OR The range of variation permitted in maintaining a
specified dimension or limit.
Electrical testing is the process of verifying and validating the electrical properties of an
electrical system or device. It is essential to ensure that electrical systems are safe, reliable, and
efficient.
There are various types of electrical testing, including insulation resistance testing, high voltage
testing, ground resistance testing, power quality testing, and many others. The choice of testing
type depends on the system or device being tested and the requirements for safety and
efficiency.
Electrical testing standards provide guidelines for the electrical testing process. The
International Electrotechnical Commission (IEC) and the National Electrical Manufacturers
Association (NEMA) are two organizations that develop and maintain electrical testing
standards.
Electrical testing standards help ensure that electrical systems and devices are safe, reliable, and
efficient. They also help improve the testing process's efficiency, reduce costs, and increase the
quality of the products, systems, or services being tested.
A routine test is a test to which each device is subjected after or during manufacture. The test
helps identify failures and/or unacceptable tolerances in manufacturing that functionality tests
may not detect and may create an electrical hazardous situation.
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Type tests are generally performed on any equipment conforming to relevant National/
International standards to validate the design and to demonstrate its functional requirement
meeting the intended application and reliable performance during its service life.
Special tests are performed upon customer request.
Switching impulse voltage test. Measurement of dissipation factor (tanδ) and capacitance.
Measurement of zero sequence impedance(s) Determination of sound level. Measurement of
harmonics of the no-load current.
The special tests of transformer are performed depending upon customer's requirements to
gathering the information which is useful during the operation and maintenance of the
transformer. Tests on accessories e.g. buchholz relay, oil preservator, temperature indicators,
pressure relief devices etc
Supplementary Test: Supplementary tests are those which are conducted on the transformers
when additional information is required in respect of a particular transformer, either by the
manufacturer or by the purchaser,
Direct method of testing : In this method the machine is directly connected with the load or a
pulley and brake arrangement is provided or a electrical load may be connected in the form of
a calibrated machine Brake test and calibrated machine test are the examples of direct tests.
Direct tests involve running the machine at its rated load and measuring the electrical quantities,
such as voltage, current, and power output, directly using instruments. These tests can provide
accurate results but may be time-consuming and require specialized equipment.

Indirect tests, involve measuring the machine's performance by observing its behavior and
comparing it with expected results based on mathematical models. These tests can be done without
actually running the machine at its rated load and can provide useful information about the
machine's characteristics and performance under different operating conditions. However, they may
not be as accurate as direct tests, especially if the machine is operating outside of its normal range.

Direct tests are preferred for accurate measurements of electrical quantities, while indirect tests are used for
quick evaluations of machine performance and characteristics.

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State any two advantages of direct testing method.

Advantages of Direct Testing Method:

1. The efficiency can be determined at any load because constant losses are known.

2. Power required for this test is small.

3. This method is quite economical and convenient.

4. Results are actual / Gives most accurate results.

5. Very simple method.

6. Very useful for small capacity machines

7. Very simple and easy calculations.

8. Generally, no assumptions are required.

9. As the machine is directly loaded and performance is determined hence its temperature rise at full
load, commutation problems, real time problems, actual ground results are accurately known.

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 MEE Unit- III: Testing and Maintenance of rotating machines

State the permissible limits for variation of :1) Voltage 2) Current 3) Speed 4) Frequency

All electrical machines are mounted on the foundations so that its static load and also the dynamic
load of the rotating machine is transmitted to the ground. The foundation should be strong in
construction so as to prevent displacement and vibration of the running machines. A solid concrete
structure is essential for foundation. The machine is connected directly to the foundation with the
help of foundation bolts, nuts. The basic requirement of foundation are
(a) It should be horizontal
(b) It should be rigid
(c) It should be free from vibrations and displacement.
Common Troubles in Electrical Installation
(i) Foundation not strong.
(ii) Foundation structure, nut-bolt not aligned properly.
(iii) Concrete foundation if not cured for a period of time may create problems.
(iv) There may not be sufficient space for foundation or around foundation to fix accessories.
(v) Sufficient space around the installation may not be available for the operator to operate the
control devices.
(vi) May produce vibration if installation is not horizontal and rigid.

Machine Foundation
1. Factors Involved in Designing Machine Foundation
Foundations help in static or dynamic load of the machines to the ground. For designing the
foundation for the machine the factors like weight of the machine , its H.P capacity, speed of
rotation, type of drive, soil conditions, etc. must be taken into consideration . Machine foundations
are not based on any definite calculations, but they are dependent on practical , industrial experience
and the data available. The machine foundation should satisfy the following requirements.
1. The foundation should be horizontal in level.
2. The foundation must be rigid.
3. It should be free from vibrations.
4. It should transmit both static and dynamic weight of the machine to ground
5. The foundation should be free from defects like cavities, pits, surface cracks etc.
6. The foundation should be made from concrete mix i.e. cement, sand water in definite
proportion.

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7. The design of foundation should ensure against sinking of foundation by distributing the
load over as much as soil area, in relation with soil bearing capacity.
8. The foundation should not slide over the soil due to horizontal thrust of running machine.
This is achieved by sufficient frictional resistance between foundation błock and soil.
9. The foundation should be so designed that the resultant force posses within the block to
prevent turning of the machine.

2. Following arrangements can be done to minimize the vibrations

I. The machine itself should be isolated from the adjacent structure by vibration
absorbing material so that the vibrations caused may not induce any adverse effect
on the neighbouring structures.
II. The machine must be rigidly bolted to the foundation.
III. The insulating material is laid between bed-plate of the machine and foundation
block.
IV. The isolation material is laid between the foundation and the ground on which it is
supported.
V. The isolation material in the form of spring is laid between bed-plate of machine
and Foundation work.

3. List out basic requirements of foundation

Basic Requirements for the Foundation:
1. The foundation should be strong / rigid preferably of concrete which should be able to carry
the superimposed loads without causing shear or crushing failure.
2. The foundation should be able to withstand against the Weight of machine, Erection weight,
Operating weight, Super imposed load weight and Accessories weight.
3. The foundation should be made of concrete with concrete ratio of 1:2:4.
4. The foundation should be of well cure before installing the machine on it.
5. Depth of foundation should be proportional to the bearing capacity of soil.
6. The surface of foundation must be well protected from the machine etc.by means of suitable
chemical coating or suitable chemical treatment.
7. Level of plinth of foundation should be above the maximum flood level of the site.
8. The location of foundation is such that there should be sufficient space all around the
machine.
9. The combined centre of gravity of machine and foundation should be as far as possible in the
same vertical line as the centre of gravity of the base plane.
10. All amplitudes / settlements / limits should be within permissible limits which are prescribed
by the machine manufacturers.
11. The dimension of foundation should be somewhat more than actual requirements and
proportional to safe bearing capacity of soil.

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12. The foundation should be sufficiently rigid to withstand possible horizontal thrust caused
by machine while in operation.
13. The surface of foundation should be perfectly plane to avoid misalignments.
14. The depth of the foundation should be as given in the following table for better operation of
machine.

State factors involved in designing the machine foundation.

1. Consider Static weight of the machine and accessories.

2. Also consider magnitude and characteristics of dynamic loads imposed by the machine during
operation.
3. The foundation should be able to carry the superimposed loads without failure.
4. The groundwater table should be confirm.
5. The foundation of a machine should be sufficiently rigid to take care of vibration and to
maintain proper alignment between the motor and the load.
6. The foundation should absorb the vibrations created by the machine while operating at its
full capacity.
7. The frictional resistance between foundation block and the soil should be sufficient to
withstand the possible horizontal thrust caused by machine while in operation.
8. The dimension of foundation should be proportional to safe bearing capacity of soil.
9. The dimension of foundation block should be sufficient that the resultant of all the forces should
pass within the foundation block.
10. The combined centre of gravity of machine and foundation should, as far as possible, be in the
same vertical line as the centre of gravity of the base plane.
11. No resonance should occur; hence the natural frequency of the foundation–soil system should
be either too large or too small compared to the operating frequency of the machine. For low-speed
machines, the natural frequency should be high.
12. Machine foundations should be taken to a level lower than the level of the foundations of
adjoining buildings.
13. For concrete masonry foundations a mixture of cement, sharp sand and broken stones in the
volume ratio of 1:2:4 respectively should be used.
14. The foundation should be allowed to stand for at least 7-10 days, before the machine is put onto
it.
15. The foundation must be protected from machine oil by means of acid-resisting coating or
suitable chemical treatment.
16. The following size of depth of foundation:
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What are the effects of misalignment on the performance of machine?

The shaft, pulleys, couplings of driven and driving machine need proper alignment. If it is not
ensured the following are the effects.

a) Direct Coupled Drives: For direct coupling drives the misalignment during installation give rise to:(ii)

1. Increase load on bearing. 2. Excessive vibrations in driving and driven machines.

3. Increase noise level 4. Increases stresses on coupling & shaft.
5. Final effect of this the bending of shaft, damages to bearing & overloading of driving
machine causing it failure
6. Overall performance of machine reduces
7. It reduces the machine’s life and causes a decrease in motor efficiency,
8. Misalignment phenomenon is one of main causes for economic losses in industry.
Effect of misalignment on the performance of machine: (indirect coupled)
1. The life of belt, rope , chain & gear is shorted.
2. Produces distribute vibration. 3. Increase noise level. 4. Bent shaft.
5. Worn out bearing. 6. Final effect of this is early wear & tear of both driven & driving machine

Explain the significance of open circuit voltage ratio test on three phase slip induction motor
The open circuit voltage ratio test is an important test carried out on a three-phase slip induction
motor. In this test, the stator winding of the motor is supplied with a rated voltage and the rotor
is kept open. The voltage across each phase is then measured and the ratio of these voltages is
calculated.
The significance of this test lies in the fact that it helps to determine the following parameters of
the motor:
Turns ratio: The turns ratio of the motor can be calculated by comparing the measured voltages
with the rated voltage. This helps in determining the number of turns in each phase winding of
the motor.
Impedance: The open circuit voltage test helps to determine the impedance of the motor. By
knowing the impedance of the motor, the efficiency and power factor of the motor can be
calculated.
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Identify any winding faults: The open circuit voltage ratio test can also help in identifying any
faults in the motor windings. If the measured voltages are not in proportion to the rated voltage,
it may indicate that there is a fault in one of the windings.
Efficiency calculation: The open circuit voltage test is also used to determine the efficiency of the
motor. This is because the ratio of the measured voltages can be used to calculate the copper
losses in the motor.
Overall, the open circuit voltage ratio test is an important diagnostic tool for evaluating the
performance of a three-phase slip induction motor, and can provide valuable information about
the motor's efficiency, impedance, and winding faults.
Describe procedure and objective of reduced voltage running up test on 3ɸ Induction motor.
Ans:
Objective of Reduced Voltage Running up Test on 3ɸ Induction Motor:
1. To determine the ability of motor to run equal and nearly equal to rated speed of the motor
even at reduced voltage in the both directions – forward & reverse.
2. To see whether there is any tendency of cogging & crawling presents in the motor.
3. This test is conducted to check the noisy running of motor.
4. To see whether, if noise level is more than tolerance limit which may be because of damaged
bearings, also presence of loose bars & wrong connection of stator winding.

1. The motor up to 37 kW shall be supplied with reduced voltage 1 / √3 of rated value for each direction of
rotation with the help of auto transformer.

2. For motors above 37 kW, the voltage shall be 1/ √3 of rated value but motor shall be run only in the
specified direction of rotation with the help of auto transformer.

3. The speed in this case is also recorded. In both the cases, the speed should be equal and nearly equal
to rated speed of the motor.

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Prepare trouble shooting chart for 1Φ Induction motor

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Limits of Voltage, Current, Frequency and Speed for Safe Working of Electrical Machines
➢ 1. Voltage variation should not be ±5% of rated voltage.
2.Current should not exceed rated current.
3.Temperature rise should be within limits.
4. Frequency should not vary by ±1% of rated frequency
5.Should work within ± 2% of rated speed.
➢ 6. There should not be magnetic locking for 3 phase induction motors.
7. Uniform air gap between static and rotating part.
8. Perfect bearings, no play.
9. No dust-dirt moisture deposition.
10. No noise, quiet operation.
➢ If the above conditions are fulfilled, the machine is said "running normal".
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➢ But due to various reasons, faults are developed in the machine and it gives trouble
in working. Its working is not satisfactory.
➢ Trouble shooting charts showing troubles and reasons of these troubles are given in
further sections
Internal and External Causes for failure and Abnormal Operation of Equipment’s
Internal Causes
1.In some unavoidable situation the machine may have to be run "over loaded" for a longer-period
which causes temperature rise beyond the permissible limit.
2. During normal working shot-circuit may occur due to some reasons.
3. Some live terminal touches the metallic part developing phase to ground fault.
4. Rotating part and stationary part shall have uniform air-gap. If not, then the behaviour of
machine becomes abnormal.
5. Single phasing means one of the three phases become open circuited and the load is shared by
Only two phases instead of 3-phases. Hence over loading on phases and behaviour becomes
abnormal.
6. Due to facing of stator and rotor teeth sometimes the teeth become magnetically locked and
motion of motor does that possible.
7.Phase winding may electrically touch each other may create problem.
8. Some turns of phase windings get shorted.
9. Worn out bearings, oiling/ lubrication may not have been done frequently involving more
mechanical frictional losses.
10.Unbalance rotating weights and fault in rotor may also the cause of abnormal behaviour of the
machine.
External Causes
These causes are external to the machine from supply to the terminal box of the machine.
1. A 3-phase machine is supplied with 3-4ine wires L1, L2, L3 . These are called as lines. If the
fault is developed in the feeder/ Distributor line only two lines will supply the equipment. The
two lines supply the power to 3 phases of machine and two phases become excessive of load &
overheating take place and machine condition becomes abnormal (single phasing on distributor
side).
2. Sometimes due to wind, rains, birds etc. short circuit occurs in the supply system which
affects working of machine instantly.
3. If supply system generator working in generating station is subjected change in the speed of
prime mover ,then supply frequency changes which affects the working of machine connected to
this supply system.
4. Sometimes in the generating station/ receiving station/ substation there occurs overvoltage or
under voltage which affect the normal working of the machine.
5. Some times negative sequence currents are developed due to unbalance supply which affects
the normal working of the machine.

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6. If external load on the machine is sustained for a length of period, the insulation may start
burning due to excessive temperature rise.
These external conditions affect the performance of machine and abnormalities are
developed.
Test on IM

1. No load test, measure winding resistance for a single phase induction

motor and determine its performance
No load test is routine test carried out on single phase induction motor. This test is intended to find out no
load current, core loss, friction and windage losses. Stator of single phase induction motor consist of main
winding and starting winding placed at 90° electrically apart to produce rotating magnetic field. In single
phase induction motor main winding is designed for low resistance and starting winding for high resistance.
Phase difference in both winding is produced by connecting capacitor in series with starting winding.

Procedure
Measurement of Winding Resistance
1) Disconnect the single phase, capacitor start induction run motor from the supply.
2) Open the terminal box.
3) Discharge the capacitor.
4) Separate the windings and capacitor terminals.
5) By using Multimeter identify the winding terminal pair by continuity test.
6) Measure the resistance of each winding by Multimeter.
7) Note down the values in the observation table.
8) Reconnect the main and starting winding along with capacitor and centrifugal switch.
No Load Test
1) Make the connections as per the circuit diagram.
2) The motor is run at no-load with the running winding excited at normal frequency
and voltage until the power input is constant.
3) Readings are taken of volts, amperes and watts input at rated frequency. The voltage adjustment is
accomplished preferably by a variable-voltage transformer.
4) Switch off the supply.

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2. To perform no load and blocked rotor test on three phase induction

motor to determine the equivalent circuit parameters.
Practical Significance
No Load test is performed to obtain magnetizing parameters in induction motor’s equivalent circuit. A
block rotor test is performed to calculate leakage reactance and winding resistance in induction machine
motor’s circuit.
No Load Test
It is a type of Routine test that gives information about core loss or iron loss, friction and windage losses,
magnetizing current, no load power factor and parameters of magnetizing branch of equivalent circuit i.e. I0,
Iµ, IW, R0, X0. If the motor is run at rated voltage and frequency without any mechanical load, it will draw
power necessary to supply the no load losses. The no load current will have two components. The active
component and the magnetizing component, the former being very small as the no load losses are small. The
power factor at no load is therefore very low. The no load power factor is always less than 0.5 and hence at
no load one of the wattmeter at input side reads negative.

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 MEE Unit- III: Testing and Maintenance of rotating machines

A) For No Load Test

1) Select the instruments and meter ranges as per the resources required table.
2) Make the connections as per the circuit diagram shown in Fig.
3) Switch ON the 3 phase supply, start the motor at reduced voltage and then run
at rated voltage with the help of Autotransformer.
4) Note down all meter readings.
5) Switch OFF the power supply.
Blocked Rotor Test : The stator is supplied with a low voltage of rated frequency just sufficient to circulate
rated current through the stator with the rotor blocked and short circuited. The power input, current and the
voltage applied are noted down. The power input during the blocked rotor test is wholly consumed in the
stator and rotor copper losses. The core loss is low because the applied voltage is only a small percentage of
the normal voltage. Again since the rotor is at stand still the mechanical losses are absent. Hence the blocked
rotor input can be taken as approximately equal to the copper losses.

For Blocked Rotor Test

1) Select meter ranges required for blocked rotor test.
2) Hold rotor by hand or brake system
3) Switch ON the 3 phase supply and apply voltage slowly with the help of
autotransformer so that rated current flows to motor.
4) Note down all meter readings.
5) Reduce voltage and switch OFF the power supply.
6) Using appropriate method measure stator resistance across the motor terminals
and determine per phase AC value.

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3. To perform no load and blocked rotor test on three phase induction

motor Plot the circle diagram and judge its performance
The circle diagram of an induction motor is very useful to study its performance under all operating
conditions. We get information about its power output, power factor, torque, slip, speed, copper loss,
efficiency, starting and maximum quantities etc.
The circle diagram is the graphical representation of the performance of the electrical machine drawn in
terms of the locus of the machines input voltage and current. Equivalent circuit for rotor of Induction motor
is series R-L circuit with variable load resistance, so locus of rotor current for changing load is circle. As
motor current is vector sum of constant no load current and rotor current referred to stator, locus of motor
current is also circle with changing load which is shifted by no load current as shown in diagram.
Circle diagram is locus of end of motor current vector when Induction motor is tested at various loads.

4. Perform the brake load test on the three phase Induction motor to plot the following
operating characteristics
It is a type test conducted as per IS 325 on induction motor by actually loading, to understand
performance parameters like speed, input stator current, power factor and efficiency.
Brake test is suitable for small and medium capacity motors due to non- availability of large loading
facility. Artificial loading arrangement is provided by Break-pulley and belt or rope. Motor can be tested
gradually increasing the load by tightening the tension on the belt. The spring balance readings in kg on
slack(S1) and tight (S2) side of the belt are noted and respective readings on input side of the motor such
as current, voltage, power are noted. Speed is measured. From the observations the performance
characteristics can be plotted. This test is also carried out for measurement of temperature rise of a motor.

Performance characteristics of three phase Induction motor.

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Procedure
1) Connections are made as per circuit diagram.
2) The rotor was made very much free to rotate.
3) Pour some water inside the brake drum so as to cool the rotor belt.
4) 3-Φ induction motor started using autotransformer starter.
5) Adjusted the load till current was made to rated value of motor.
6) Decrease the load step by step and note corresponding speed, load, current, voltage and wattmeter
readings.
7) At certain load, wattmeter W2 will show negative reading. Note down the line current at this point.
8) Interchange the connection of current coil of wattmeter W2 which was reading negative after
switching off supply.

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5. To perform open circuit voltage ratio test on three phase slip ring
induction motor
This test is carried out to find the voltage ratio or turns ratio. Rated voltage is given to stator winding
of slip ring induction motor and voltmeter is connected across slip rings. The voltage across slip ring=
V2 and it is the line voltage which should be divided by√3 to get VPh. The readings of V2 are taken
across different slip rings and in different positions of rotor. Average of these values is taken.

Procedure
1) Disconnect the rotor resistance starter from the slip rings.
2) Connect voltmeter across slip rings.
3) Give rated voltage (V1) to the stator winding though autotransformer.
4) Measure voltage (V2) across slip rings. Take different readings of V2 across
different slip rings and different position of rotor. Take average value.

Convert measured Stator and rotor voltages in phase values and find per phase voltage ratio
Voltage Ratio = Average of primary or Stator voltage “V1”per phase/Average of secondary or rotor voltage
“V2” per phase
Voltage Ratio = Average V1/ Average V2

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Features of Synchronous Machines

1. Synchronous motors do not self-starting torque.
2. Synchronous machine is a doubly-excited machine because it requires two input supplies – one on the stator
and the other on the rotor.
3. Synchronous machines operate at constant speed, called synchronous speed.
4. Synchronous generators can produce a voltage of constant magnitude and frequency.
5. A synchronous machine can be operated at lagging, leading or unity power factor just by changing the
excitation.
6. Synchronous motors have relatively high starting torque as compared to induction motors.
7. Synchronous motors are suitable for driving constant and slow speed (usually less than 300 RPM)
loads.
8. Synchronous machines are expensive.

Testing of Synchronous Machines

➢ List of routine tests
1. Measurement of DC resistance of windings.
2. Dielectric test by DC voltage.
3. Noise and vibration measurements.
4. A.C. H.V. Tests on stator windings.
5. Testing of insulation resistance.
6. Dielectric withstand test on field winding.
7. Air gap measurements between stator and rotor.
8. O.C. characteristics.
9. S.C. characteristics.
10. Test of synchronizing circuit.
11. Testing on voltage regulators
Temperature Rise Test
➢ This test is very important and is to be carried out on rotating as well static machines to
confirm the insulation resistance within the limit and also temperature rise in the limit
where as for windings the limit is 65℃.
➢ This test can be performed at any temperature not exceeding 40℃ and no correction is
made if ambient temperature is below 40℃.
➢ If winding resistance is greater than 0.05 Ω the temperature rise can be easily found out by
using the formula,

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𝑅𝑡2 234.5 + 𝑡2
=
𝑅𝑡1 234.5 + 𝑡1
where t1 = ambient temperature t2 = final temperature of winding
Rt1 = resistance at temperature t1 Rt2 = resistance at temperature t2
But if winding resistance is less than 0.05 Ω the method explained above does not give accurate
results so oil temperature is measured by
thermometer to work out the temperature rise.
➢ The limits of temperature rise as per IS 2026 are as follows:
For winding
The winding is connected between supply and average temperature is found by finding
increase in resistance. It should not be more than 55° C. [If ambient temperature is 30° C,
maximum winding temperature should not exceed 30° C+ 55° C= 85° C]
Overspeed Test on Synchronous Motor
➢ Generally this type of test is not applicable to motors which receive the electric supply at a
constant frequency such as induction Motor.
➢ But overspeed can occur occasionally in such cases, this test is a must. (In synchronous
motor this test is essential, also for traction motors too).
This test is a basic test. For traction motor it is a routine test
➢ To check the healthiness and quality of rotor, end coils, bearings, smooth air-gaps, glass
bindings etc. Under over speeds.
➢ Procedure: By speed changing mechanisms the speed of the motor is adjusted to 120%
to 150% of its normal speed on load (when motor is hot). The time duration of this
overspeed is of 2 minutes.
➢ After two minutes the speed is brought to its normal value kept running for some time and
then the motor load is taken off and motor is stopped.
➢ By visual inspection the above things are observed. If these are not affected and damaged
then the capability of motor to run for overspeed for a minute is tested.
➢ In case of hydro or thermal turbine driven generator sometimes there is a overspeed loss of
load suddenly (transient). The generator has to be carefully checked for mechanical
integrity before over speeding by prime-mover.
Test is in steps by 115% speeding and observe that machine is ok. At this test excitation shall be
reduced to limit the increase in voltage
H.V. Testing
High voltage tests are carried on different machines to check the healthiness under high
voltage for a shorter time to check the quality of insulation resistance.
In this test specified voltages is applied between various windings and earth. This test

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should be carried out together with the insulation resistance test at manufacturer's works.
Generally high voltage test is applied only if insulation resistance is less than the specified limit.
Method of testing
The test shall be made with alternating voltage of any convenient frequency between 40 Hz to 60
Hz. The test voltage should be of sine waveform (approximately).
Duration
The test is started by applying 1/3 of the test voltage and then voltage is increased to full-test
voltage in accordance with the

Insulation Resistance Test:

This test checks the weakness of insulation, damaged insulation, etc.
The insulation resistance between following parts is to be measured:
1. Stator phase winding earthed frame
2.Rotor winding - earthed shaft
3.Phase winding - phase winding
4.Pedestal insulation
5.Bearing insulation
The insulation resistance test reveals the health of insulation.
The presence of moisture in insulation changes its insulation resistance value. The
moisture can be taken out by drying out process. For this drying out process, the winding is
allowed to carry current for certain duration of time, so it heats up and creates temperature
radiant i.e. difference in temperature along the thickness of insulation. This temperature
gradients causes flow of heat from inner surface of insulation to outer surface of insulation. In
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doing so, the moisture is dried out. This process is known as drying out. The rate of heat
dissipation can be increased by increasing the temperature gradient.
For this, the winding is allowed to carry current and forced air is passed on the winding surface.
Thus the temperature difference increases and temperature gradient increases.
The insulation resistance is preferably measured after drying out test to get accurate results.
Rating of megger: The megger rating is specified in volts. For measuring insulation resistance of
winding rated upto 1000 volt, a megger of 500 volt can be used.
For winding rated above 1000 volt, a megger of 1000 volt should be used.
AC resistance: The armature winding of alternator or synchronous motor carries alternating
current. So skin effect is present in the winding. The skin effect causes increase in resistance. The
ac resistance is thus greater than DC resistance.
The resistance measured by above methods is DC resistance, it can be converted to equivalent ac
resistance by following expression.
𝑅𝑎𝑐 = _______ × 𝑅𝐷𝐶

This Rac is considered in calculation part of finding regulation of alternator.

For measuring insulation resistance of stator winding, a motor driven megger of 1000 volt
or 2500 volt DC rating is used.
The megger terminals are connected as shown in Fig. 3.9.9. i.e. one terminal to any of the phases
(say phase B) and other terminal to frame of the synchronous machine. The frame of the machine
is properly earthed. Megger generates dc voltage that gets applied across the winding and frame.
The circuit behaves as a capacitive circuit i.e. two metal plates (B phase conductor and
frame) separated by a dielectric (B phase conductor insulation). So, initially a large charging is
drawn which gradually decays down after some time.

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So the pointer of megger shows initial dip in reading i.e. less resistance because the capacitor
initially acts as short circuit i.e. less resistance and more current.

As the capacitor is charged, the current decays down and now the pointer moves gradually
and then indicates value of insulation resistance.
Thus the testing condition should be critically specified i.e. the time between application of
voltage through megger and observation of pointer on scale should be critically specified.
The time of 60 second is sufficient to get accuracy in measurement. i.e. megger is switched
ON and reading is taken after 60 sec. The working temperature of winding is assumed to be 70°
C.
This test is also known as IR test.
The insulation resistance In R60 (mega ohms) is given by following expression.
𝑉
𝑟𝑎𝑡𝑒𝑑
InR60 = 1000+0.01 𝑃

where Irated = rated voltage across the machine winding in volts

P = Rated output of synchronous machine (in kVA)
The suffix 60 denoted that test observations are to be taken after 60 seconds.
As stated earlier, this test is carried out after drying out state. (i.e. winding temperature is
increased) A temperature of 70°C should be reached and then megger test is to be performed.
The standard values of insulation resistance at 70℃ are mentioned below:

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 MEE Unit- III: Testing and Maintenance of rotating machines

The measured insulation resistance should not be less than above values. The insulation resistance
of synchronous machine at different level.
Dielectric Test on Armature (Stator) and Field (Rotor) Windings
These test are performed with
(A) AC voltage
(B)D.C. voltage.
Prior applying these tests, the power frequency voltage withstand test is performed which
is described in brief as follows.
"Power frequency voltage withstand test"
Specified values of power frequency test voltages (2u+ 1) kV are applied for a specified
time (1 minute) between the windings and the earthed frame of a 3-phase synchronous machine.
At this other phases are grounded. The machine should pass this test without any damage to the
windings and other insulations.
If the machine passes the test then dielectric tests are conducted.
(A)Dielectric test with A.C. voltage
➢ Aim: Aim of the test is to prove the voltage withstand capability of insulation of the
machine windings of stator and field.
➢ In testing, the start winding should withstand the specified test AC. voltage recommended
by the manufacturer without failure.
➢ Test voltage for stator winding = (2u + 1) kV r.m.s. for 1 minute. For Rotor winding- 10
times rated field voltage but minimum of 1500 Volts, A.C. rims.
B) Dielectric test with D.C. voltage
➢ In this test a rectified D.C. voltage of value 1.7 times the r.m.s. rated A.C. voltage is
applied for a period of 1 minute.
➢ Leakage current is also measured.
Dielectric test is needed for every machine whether static or rotate
Phase Sequence
➢ In case, the load demand is increased, a 2nd (incoming) machine is to be electrically
connected to the bus bar or 1st machine in parallel to meet the increased demand of power.
To put incoming machine in parallel to the bus-bar is called as synchronising.
➢ Proper synchronism will be when

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 MEE Unit- III: Testing and Maintenance of rotating machines

(i) Terminal voltage of incoming machine is same as bus-bar voltage.

(ii) Frequency of incoming machine must be same as bus-bar frequency.
(iii) Polarity of incoming machine must be same as bus bar polarity.
(iv) Phase-sequence RYB of the incoming machine must be same as the bus bar phase sequence
RYB.

The phase sequencing is required for securing given rotation direction or for correct
phasing of generator prepared for synchronizing to bus bar.
➢ Note that the last condition if not full filled, the parallel operation will not be satisfactory.
The phase sequence is checked by "phase sequence Indicator".
Leakage Current Test
The leakage current should be negligibly small so that there is no risk to the operator and machine
is safeguarded. The limit for the current so measured by the current circuitry shown in the diagram
shall not be more than 2.5 mA.

Procedure
➢ The motor is applied with a voltage = 1.1 × rated voltage through auto transformer.
➢ An external circuit consisting of a mili ammeter and a resistance R = 2000 ± 50Ω value is
connected as shown in the diagram. For the perfect condition of the insulation of the motor
, the mili ammeter reading should not exceed 2.5 mA.
Various Tools used for Repairs and Maintenance
(i) Bearing Puller: For taking out and refitting of bearings.
(ii) Filler gauge: For checking the air-gap between two parts.
(iii) Dial tester: Checking shaped, alignment of shaft
(iv) Growler: For finding the shorted turns of coils.

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Bearing Puller

➢ This tool is very necessary for repairs for matching for taking out
the damaged bearing and put a new bearing on the shaft.
➢ Tools of this type are also useful for withdrawing, sprockets,
gears etc. When the space at the back is restricted.
➢ Fig. shows a bearing wedge applied to the driving end bearing of
a motor rotor where the use of ordinary drawing gear is often
difficult due to limited space and danger of damage to windings.
In such situation this tool is most importance.
Filler Gauges
➢ The gauge shown in the figure has different blades of different thicknesses to check the
gaps between two parts.
➢ The air gap should always be checked after dismantling and
reassembly, it is also a part of routine maintenance, particularly in
case of sleeve bearing machines.
➢ In making this measurement a special long filler gauge is
inserted through the apertures which are often provided in the end
bracket for the purpose.
➢ These apertures are usually plugged to exclude dirt, and the
screwed plugs must be removed to permit insertion of the filler.

Dial Test Indicator

Following sketch shows a dial indicator consisting of main
parts
(i) Indicator (ii) Stand (iii) Base (iv) Holder
By this indicator the shape (whether true or damaged) of
various rotating parts of machine such as shafts, rotors,
commutators are checked. These consists of system of
interlink livers/ Gear wheels. By this the small moments are
magnified to enable to read them. Any height or any angle
can be set by moving system.

These are also used to check alignment of shaft:

o The indicators are generally provided with 0.01 mm
scale divisions. During measuring the base is placed on a

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 MEE Unit- III: Testing and Maintenance of rotating machines

stationary support and

the measuring rod is set perpendicular to the shaft axis.
o Then the rod is made to bear upon the surface being checked. Prior to taking the run-out
reading, make sure that the indicator is positioned correctly.
o For this purpose, lightly tap the indicator case, the inter, in the case, will oscillate. If after
oscillation is set correctly.
Spirit Level Spirit level has a glass tube and very true surface. Bubbles moves inside right- or
left-hand side.
➢ When installing electrical machines, checking
of foundation for correct level is to be carried
out. For this purpose, hydrostatic or spirit level
is used. By adjusting the foundation plate by
giving packings till the bubble in the glass tube
is at the centre the adjustment is continued by
trial-and-error method and finally levelling is
achieved.
➢ If the level is not true, then rotation will
produce vibrations and bearing and shaft may
be damaged. Hence it is importance to give the
true level to the foundation plate of the machine
making use of spirit level.

Megger: It is a device to check continuity, short circuit approximate value of high resistance in
MΩ.
Main parts
1. D.C shunt generator hand driven producing about 500 volts.
2. Current coil 4. Pressure (voltage) coil
3. Spindle and indicator 5. Permanent magnet
These parts are arranged in the box. Glass window for dial reading and handle for rotation
of armature of D.C. generator.

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➢ For measurement of insulation resistance, a megger is used.

➢ One terminal of the megger is connected to winding terminal and other is connected to
earth or frame of equipment.
➢ In case of fault between windings, both the terminals are connected to separate winding
terminals and the armature of the generator is rotated at constant desired speed.
➢ If there is fault between the windings or winding and earth, the pointer will deflect at zero
mark, otherwise it measures the insulation resistance in mega-ohms. From this value of
insulation resistance, quality of insulation is determined.
Earth Tester
➢ The resistance of earth can also be measured by an earth tester as shown in Fig. The
earth tester is special type of megger and it has some modifications in comparison to a
megger as shown
(i) A Rotating current reverse and (ii) A Rectifier.
➢ Both these additional features consists of
simple commutators made up of ’L’ shaped
segments. They are mounted on the shaft of the
hand driven generator. Each commutator has four
fixed brushes. One pair of each set of brushes is so
positioned that they make contact alternatively
with on segment and then with the other as the
commutator rotates. The second pair of each of set
brushes is positioned on the commutator so that
continuous contact is made with one segment
whatever the position of the commutator.

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Growler
➢ It is a equipment used for finding shorted turns of armature coil or stator/rotor winding. It
is essentially a single winding transformer.
➢ Low voltage or 230 V. AC is applied to a growler’s winding. Hence A.C. flux is produce.
This winding acts as a primary winding of transformer.
How to locate a shorted armature coil?
➢ The armature under test is put on these coil assembly and with a small motion the armature
is rotated.
➢ When the shorted coil comes under the influence of
the growlers coil (Magnetic field of this coil) it acts as a
short circuited secondary of the transformer and hence a
very large current flows through two
coil sides.
➢ Very thin iron strip like hack-saw blade when put on
the armature slot containing any one side of the shorted
coil a rapid vibration is produced on the blade. This is the
slot of shorted coil.
Thus growler finds the shorted armature coil

Gauge of Conductor Wire

The wire size (conductor size) is not expressed in terms of area or diameter but for
simplicity it is expressed in the standard form called as B. S. W.G. (British Standard Wire Gauge)
the smallest gage is 40 which has a diameter of 0.1219 mm and bigger gauge is 0 which has diameter
of 12.7 mm.
Procedure of checking of wire gauge: If the conductor is enamelled then, scratch out the enamel
and then insert the conductor in the approximate gap of the various gauge numbers. For example, if
the conductors enters in gauge No. 3 just easy; in 4 it is
not easily entering and it is very loosely entering in 2,
then 3 is the gauge
Number of that wire. It should be noted that the higher
the number of wire gauge the smaller is the diameter.
Some Wires are having one solid conductor. Some
wires are having two conductors, 3 conductors. Such
wires are called as standard conductors.
These wires are expressed as follows:
➢ 7/20 wire means it has 7 strands and gauge of one
strand is 20 SWG.

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 MEE Unit- III: Testing and Maintenance of rotating machines

➢ The wire 40/0.1930 means, it has 40 strands and each strand has a diameter 0.1930 mm.
For selecting a wire for a particular work, the standard tables are available in the pocket size diary
of an engineer. Generally for a small house, whose current requirement is not more than 5 Amps; a
suitable CTS or PVC wire of size 1/18 is used. 1/118 means the wire has one conductor .e. One
strand which has a gauge number of eighteen.
A test light, test lamp, voltage tester,
Test lamp
A test lamp is a portable lamp in socket
with free leads to connect to various points
of a faulty circuit to locate a defect (as a
blown fuse).

Mains tester is a piece of electronic test equipment used to determine

the presence of electricity in a piece of equipment under test.
A test light is simpler and less costly than a measuring instrument such
as a multimeter, and often suffices for checking for the presence of
voltage on a conductor.
The tester works by detecting the electric fields associated with AC
voltages. These fields are usually present near the live conductors,
hence the reason why there is no requirement for direct contact with
the conductors.

A multimeter (also known as a volt-ohmmilliammeter, volt-ohmmeter or VOM) is a measuring

instrument that can measure multiple electrical properties.
A typical multimeter can measure voltage, resistance, and current, in which case can be used as
a voltmeter, ammeter, and ohmmeter.

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 MEE Unit- III: Testing and Maintenance of rotating machines

Wrench or spanner is a tool used to provide

grip and mechanical advantage in applying
torque to turn objects—usually rotary
fasteners, such as nuts and bolts—or keep them
from turning. A set of metric spanners or
wrenches, open at one end and box/ring at the
other. These are commonly known as
“combination” spanners.

A screwdriver is a tool, manual or powered, used for turning screws.

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 MEE Unit- III: Testing and Maintenance of rotating machines

UNIT 3 Testing and Maintenance of rotating machines Marks 20

1. State the use of following tools – i) Filler gauge ii) Bearing puller iii) Spirit level iv) Growler v)
Dial Indicator vi) Earth tester
2. Explain with neat circuit diagrams the procedures to perform no load tests on three phase
induction motor.
3. Explain the significance of open circuit voltage ratio test on three phase slip induction motor
4. State the objectives of testing of electric machine.
5. List out eight different tools used in electrical maintenance.
6. State two electrical faults in electrical machine.
7. State the effects of misalignment on direct coupled drives.
8. State the tolerance limits for the following: 1) No load current for single phase transformer 2)
Speed for three phase induction motor
9. List the different methods of testing of electrical equipment.
10. List out eight different tools used in electrical maintenance.
11. State any two advantages of direct testing method.
12. Describe procedure for blocked rotor test to be carried out on 3ɸ Induction motor with neat
diagram
13. Explain with circuit diagram the open circuit voltage ratio test on 3 phase slip ring induction
motor.
14. Describe procedure for break load test to be carried out on 3ɸ Induction motor with neat
diagram.
15. Explain the need and steps to conduct the reduced voltage running up test on the three phase
induction motor.
16. Explain moisture proofness test conducted on single phase induction motor.
17. Explain the significance of open circuit voltage ratio test on three phase slip induction motor.
18. State factors involved in designing a machine foundation.
19. Explain with neat circuit diagrams the procedures to perform no load and blocked rotor tests
on three phase induction motor.
20. Explain with diagrams the synchronous impedance method of finding regulation of alternator.

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