TESTING OF H.T.

MOTORS
DISCUSSIONS WITH CEMENT INDUSTRY EXECUTIVES ON WORKS TESTING OF HT MOTORS ON 5th NOVEMBER, 2009.

PC JAIN AGM(IMS)

RANGE OF MOTORS & TYPE OF M/Cs.

RANGE : 140 KW TO 40 MW
TYPE OF M/Cs INDUCTION SYNCHRONOUS : SLIP RING INDUCTION MOTORS : SQ. CAGE INDUCTION MOTORS : MOTORS & GENERATORS

VFD MACHINES ( VARIABLE FREQUENCY DRIVE ) FLAME PROOF , PRESSURISED MACHINES.

TYPES OF TESTS
1.0 IN PROCESS OR STAGE TESTS : MEASUREMENT OF RESISTANCE, IMPEDANCE, IR , PI, TAN DELTA AND HV TEST . MAGNETIC CENTRING . 2.0 ROUTINE TESTS : TO CHECK GENERAL PERFORMANCE OF ASSEMBLED MOTOR ON TEST BED. 3.0 TYPE TEST : DONE ON NEW DESIGN MACHINES OR ON CUSTOMERS REQUIREMENT.OBJECTIVE IS TO PROVE THE DESIGN.

LIST OF ROUTINE TESTS.

1.0 COLD RESISTANCE.
2.0 PHASE SEQUENCE / DOR 3.0 MECHANICAL RUN OF MOTOR AT NO LOAD.

4.0 NO LOAD CURVE , SHAFT VOLTAGE &

VIBRATIONS. 5.0 LOCK ROTOR TEST.

6.0 POLARISATION INDEX ( >1.5).

7.0 AC H. V. TEST AT (2XU+1) FOR 1 MINUTE.

TYPE TESTS
1.0 NO LOAD SATURATION CURVE( FROM 125 % RATED VOLTAGE TO 25% RATED VOLTAGE.) 2.0 DETERMINATION OF STARTING CURRENT & STARTING TORQUE BY LOCK ROTOR TEST. 3.0 LOAD POINTS AT 100 %, 75% & 50 %. 4.0 OVER LOAD AT 160% RATED CURRENT.(SUBJECT TO TEST PLANT LIMITATION. 5.0 NOISE LEVEL MEASUREMENT. 6.0 OVER SPEED AT 120 % RATED SPEED FOR 2 MINUTES. 7.0 TEMPERATURE RISE TEST.

TEMPERATURE RISE TEST METHODS

1.0 DIRECT LOADING METHOD(UP TO 1300 KW) 2.0 BACK TO BACK METHOD(INDENTICAL MACHINES)

3.0 MIXED FREQUENCY METHOD : A COMBINATION

OF 50 Hz & 40 Hz SUPPLY IS FED FROM TWO INDEPENDENT SOURCES.

SPECIAL TESTS 1.0 IP 55 (IInd NUMERAL) 2.0 TAN DELTA TEST ON MACHINES ABOVE 3.3 KV

3.0 IMPULSE TEST AT (4 U+5) KV . U=LINE VOLTAGE

4.0 RETARDATION TEST. 5.0 PRESSURISATION TEST. 6.0 VOLTAGE DECAY 7.0 WORKING OF BACKSTOP 8.0 EXTENDED NO LOAD RUN

EFFICIENCY CALCULATION
BY SUMMATION OF LOSSES METHOD.

-FRICTION & WINDAGE LOSSES FROM NO LOAD CURVE -IRON LOSS FROM NO LOAD CURVE -STATOR Cu LOSS ( 3X Isq.R ) -ROTOR Cu LOSS (Slip X AIR GAP POWER) AIR GAP POWER= INPUT-St. Cu LOSS-IRON LOSS -STRAY LOAD LOSS = 0.5 % OF OUTPUT -OUTPUT=INPUT-LOSSES -EFFICIENCY= (OUTPUT/INPUT)X100

ACCEPTANCE NORMS AND TOLERANCES

AS PER IS 325 : TOTAL LOSSES POWER FACTOR (Min 0.02 & Max 0.07) STARTING CURRENT STARTING TORQUE PULL OUT TORQUE RESISTANCE VARIATION(M/C TO M/C) RESISTANCE VARIATION(PH TO PH) PHASE CURRENT VIBRATION AS PER IS NOISE AS PER IS

: +10% : 1/6(1-Pf) : +20% : -15%,+25% : -10% : +/-10% : +/-2% : +/-2% 12075 OR VDE 12005

INSULATION RESISTANCE (MIN. VALUES) M/C VOLTAGE (KV) IR(AMBIENT) IR(75 C)

UP TO 1.0 KV
UP TO 3.3 KV UP TO 6.6 KV UP TO 11.0 KV

30 M OHMS
120 M OHMS 250 M OHMS 500 M OHMS

1 M OHMS
4 M OHMS 7 M OHMS 15 M OHMS

TEST PLANT FACILITIES

-15 MVA MG SET -10 MVA MG SET -5 MVA MG SET -2 MVA MG SET -1750 KVA MG SET -650 KVA MG SET -2000 KVA MG SET -HIGH ACCURACY DIGITAL INSTRUMENTATIONS -POWER ANALYSERS -NOISE , VIBRATION , TEMPERATURE MEASURING DIGITAL INSTRUMENTS. -DIGITAL CONTROL OF MG SETS& M/c U/TEST.

WHAT IS MAGNETIC CENTRING?

IT IS A SETTING OF THE MACHINE TO ENSURE EQUAL GAP ON BOTH SIDES OF THE BEARING.
THIS IS RELEVENT ONLY IN CASE OF SLEEVE TYPE BEARINGS & HORIZONTAL CONSTRUCTION. -END SHIELD MOUNTED

- PEDESTAL MOUNTED

WHAT IS MAGNETIC CENTRING?

1. Geometrical center of stator and rotor, is not the magnetic center of machine due to asymmetry of core & other components. 2. Magnetic force pulls the rotor toward center of the stator axially.
3. Motor bearing thrust shoulders are not designed to carry any axial thrust exerted from driven equipment side. 4. Motor may hunt if it is coupled off center, and specially w/o Limited End Float coupling .

MAGNETIC CENTRING 1.Ensure that the rotor is "level" before Starting the procedure . 2. Rotor should be free to rotate in bearings. (not restricted by labyrinth seals). 3.Run the motor at rated voltage /speed on no-load w/o coupling.

4.Mark a line on rotor on chalk & sharp knife(C/L).

MAGNETIC CENTRING

5. Trip the Motor , mark two additional lines by Pushing the rotor Axially.
6. If both the lines are equally spaced on either side of the C/L & total Brg clearance is O.K. (M/C -OK) 7.For machines with End shield mounted bearings, Achieve Equal clearance by adjusting shims.

8.For machines with Pedastal mounted bearings, achieveEqual clearance by shifting the stator axially. Do not Forget to check the air gap.