THE DOW CHEMICAL COMPANY MAINTENANCE PROCEDURE

ELECTRICAL G7M-0670-00
GLOBAL 13-SEP-2005
Page 1 of 18
i
OFF-LINE MAINTENANCE AND ACCEPTANCE TESTING PROCEDURES
FOR SYNCHRONOUS MOTORS

ii
Equipment Group: E061 = Electric Motors

Equipment Type: E061J = Motors: < 1000V Synchronous

E061K = Motors: 1000V< V < 6900V Synchronous (brushless type)
E061L = Motors: 1000V < V < 6900V Synchronous (brush type)
E061M = Motors: > 6900V Synchronous (brushless type)
E061N = Motors: > 6900V Synchronous brush type

Scope This procedure defines the requirements and methods for Acceptance Testing
(ACCTST and off-line Predictive/ Preventive Maintenance (OVHAUL) of electric
motors as described by “Equipment Type” category above. The intent is to
maximize the reliability of this equipment at minimum cost through the combination
of testing equipment upon installation and employment of a regularly scheduled off-
line maintenance with the ultimate objective of eliminating all unexpected failures.

Definitions
INSULATION RESISTANCE TEST: This is a quick and simple test of the insulation
resistance to earth or to another phase conductor (which, if tested, must be
disconnected from the first phase conductor at the time of testing). The test results
indicate if the motor insulation is satisfactory for energization.

MICRO-OHM RESISTANCE TEST: A test that accurately measures the current

path resistance of electrical equipment, such as motor or transformer windings,
coils, connections etc.

MEGGER: An instrument used in the Insulation Resistance Test. Resistance

measuring device that is capable of applying different voltage levels to test
insulation systems, indicating the insulation resistance value in megohms.

SURGE COMPARISON TEST: This test applies a voltage having a steep wave
front to electric motor or generator windings. By comparison of results from the test
coil to those from a known good specimen, it is capable of detecting turn-to-turn,
coil-to-coil, group-to-group and phase-to-phase winding flaws that cannot be
detected by insulation resistance, dielectric absorption or over potential testing.
DIELECTRIC ABSORPTION TEST (DA): Applying a voltage to an insulation
specimen over a length of time, taking two readings of insulation resistance
measurements at different times, and calculating the ratio between the two.
DIELECTRIC ABSORPTION RATIO TEST (DAR): Measures the ratio of two time-
resistance readings of insulation resistance, typically a 60 second reading divided
by a 30 second reading.

POLARIZATION INDEX TEST (PI): Measures the ratio of two time-resistance

readings of insulation resistance, typically a 10 minute divided by a 1 minute
reading.

DISSIPATION FACTOR TEST: Is the relationship of the AC current and the voltage
required to drive the current through or around the electrical insulation. It is the
tangent of the angle imposed between capacitive current and the voltage imposed

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ELECTRICAL G7M-0670-00
GLOBAL 13-SEP-2005
Page 2 of 18
upon it. In practical insulation specimens, it is the same number as the insulation
power factor, up to three digits.

HIGH POTENTIAL TEST: Is capable of supplying a variable voltage from zero to

several kilovolts to the test specimen, measuring the leakage current.

CURRENT PHASE ROTATION TEST: Determines the direction of phase rotation

of the electrical rotating machine while in a de-energized state.

PARTIAL DISCHARGE TEST: The weak points of the insulation are measured
directly through the monitoring of small charge fluctuations. However, this method
does not provide information on those points of insulation where partial discharge
has not occurred.

MANDATORY TEST/INSPECTIONS ( ) – These test are considered mandatory

for both acceptance testing and routine off-line PPM. A MOC approved by the
Rotating Equipment TRL is required if these tests are not completed.

SUPPLEMENTAL TEST/INSPECTIONS ( ) – In general, all tests are used for

initial acceptance testing. Routine off-line PPM tests are not as stringent and items
marked as supplemental are only to be preformed when there is a suspected
problem with the equipment. For example: If a motor trips on short circuit
protection, insulation and winding resistance tests may be used to troubleshoot the
problem. For this example case, an MOC is not required for performing the
supplemental tests. However, performing additional tests just for the sake of testing
or just because the tests have been traditionally done at a particular site is not
supported by the Electrical Discipline or Global Maintenance Leadership. An
approved MOC from the Rotating Equipment TRL is required before such
supplemental testing is initiated.

Safety Safety is an integral part of any and all jobs. As such, all applicable Corporate and
site-specific safety and loss prevention practices and procedures shall be rigidly
applied in the execution of the work described in this Practice. It is the responsibility
of the lead person administering this Practice to assure that such safety related
Practices/procedures are identified and followed by all involved.

All electrical equipment to be tested off line should be in a de-energized state by

disconnecting or RED tagging and electrically locking out the power source.

Because of inherent dangers in any high voltage work, special care must be taken
to safeguard personnel during testing and inspection of equipment. Use of personal
protective equipment is mandatory when performing these job tasks.

Caution: After completion of all DC testing, leave the windings of the equipment
just tested short circuited to ground for 5 to 10 times as long as the test voltage was
applied!

Equipment Needed The following table list the test equipment and other equipment needed to perform
this procedure.

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Field Test Equipment Other Equipment

Megger Manufacturer’s Instruction Manuals

Surge Comparison Test Set Cleaning materials

High Potential Test Set Hand tools

Thermovision Instrument Personal protective equipment such as

Nomex clothing, high voltage rubber
gloves, and flash equipment when
necessary.

Micro-Ohm Resistance Test Ammeter

Dissipation/Power Factor Test Set Voltmeter

The required frequency for P/PM inspections for electric motors is established via
P/PM Schedule the Condition Based Electrical PPM web site.

Data Form For execution of the above-mentioned Acceptance Testing and Predictive/
Preventive Maintenance tasks, a combined Data Form G7M-0670-01 is
available. This Data Form refers to the actions described on the following pages
and shall be used as a checklist and record for final data entry into the GEMTS
system. GEMTS should capture only the Service, Reason, and Cause codes,
and only test data by exception using the text comments for the work order.
Additional results or information, like replacement of electrical or mechanical
parts, modifications and notification of critical conditions, which should enter the
history or could effect the P/PM schedule should also be recorded in the text
comments of the work order.

Preparation Follow the steps below before starting the tests and inspections on the electric
motors.

OVHAUL
Step Service Action P/PM ACCTST
offline

Plan and schedule the inspection as

established via the Condition Based
1 PREP Electrical PPM web site.
 

All Motors

Perform all necessary electrical safe work

steps according to the Corporate Safety
Guidelines and local requirements. Follow
2 PREP current ‘Electrical Clearing Procedures’ for all
equipment.
 

All Motors

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GLOBAL 13-SEP-2005
Page 4 of 18
OVHAUL
Step Service Action P/PM ACCTST
offline

Review all technical specifications, operating

manuals and previous inspection data if
3 PREP appropriate.
 

All Motors

Visual and Follow the steps below to perform a visual and mechanical inspection of the
Mechanical equipment.
Inspection

OVHAUL
ACC
Step Service Action P/PM
TST
offline

Compare equipment nameplate information

data with actual operating conditions,
drawings and specifications. Check motor
1 VISIN1 nameplate data for voltage, amperage, RPM,
and bearing type. Check tag numbering for
proper and clear ID number 

All Motors

Inspect for proper anchorage and ground

2 VISIN1 connections.
All Motors  

Check for external damage, corrosion, rust,

3 VISIN1 oil leaks, etc.
All Motors  

Inspect for proper lubrication.

4 VISIN1
All Motors
 

Disassemble and check for physical damage

5 VISIN1 and general mechanical condition.
All Motors 

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OVHAUL
ACC
Step Service Action P/PM
TST
offline

Inspect all wiring for:

Good condition (proper insulation – not


frayed)
Tight connections on lugs


6 VISIN1
Proper support/condition of conduit for


control stations and actual motor junction

boxes.
All Motors  

Inspect instrumentation system (temperature

and vibration probes, differential filter
pressure, etc.).

7 VISIN1
 

E061J  

E061K  

E061L  

E061M  

E061N

Clean all surfaces, terminals, enclosures,

terminal box(s), etc. using approved methods
8 CLN and materials.
 

All Motors
Inspect sleeve bearings for wear and for
proper tolerances, alignment, etc. On line
vibration and temperature monitoring can be
use to determine the bearing condition.
 

9 BEARMO E061J  

E061K  

E061L  

E061M  

E061N

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OVHAUL
ACC
Step Service Action P/PM
TST
offline

Inspect cooling system :

Leaks, water egress


Clean, corrosion free exchangers



Proper support/condition


Pressure test of cooling system



10 COOLSY Specific inspection, according site specific

procedures can be used to determine the
cooling system condition
 

E061J  

E061K  

E061L  

E061M  

E061N

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GLOBAL 13-SEP-2005
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Electrical
Follow the steps below to perform electrical tests on the equipment.
Tests

OVHAUL
ACC
Step Service Action P/PM
TST
offline
Perform a standard insulation test by
impressing a known voltage to various
windings such as stationary, field, exciter
field and/or armature windings and measures
the resistance. This must be the first and last
electrical test performed prior to attempting
the more complex tests. Follow Megohm
Meter test instructions as per G7M-0010-01.
This formula is satisfactory for most electrical
insulation tests.
Mohms = motor rated volts + 1000
1000
Absolute minimum acceptable values
Practical values with
Volt Test Min Safety factor 10
rating Volt Mohm Mohm
MEGGER
1 4000 2500 5 “ 50 “
8000 2500 9 “ 90 “
15000 5000 16 “ 160 “
Absolute minimum acceptable values for new
or new wound motors :
Volt Test Min
Rating Volt Mohm
4000 2500 50 “
8000 2500 90 “
15000 5000 160 “

E061J
 

E061K
 

E061L
 

 

E061M  

E061N

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GLOBAL 13-SEP-2005
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OVHAUL
ACC
Step Service Action P/PM
TST
offline
Perform a Surge Comparison Test as per
G7M-0010-47 after the integrity of the
insulation has been verified. Rotor should be
removed from the stator for a more distinct
signature. If two distinct signatures appear
the insulation may indicate one of many
scenarios such as turn to turn short, coil to
coil short, phase to phase short, open
connections, partial or complete ground or
2 SURGE
reverse connection. Refer to as built or
known good wave shapes.

E061J
 

E061K
 

 

E061L  

E061M  

E061N

With a Winding Resistance Tester check the

resistance values for each set of stator and
rotor coils as per G7M-0010-09. Resistance
values should be equal to two decimals
places for each distinct group of coils.

3 OHMTST E061J


E061K


E061L


E061M 

E061N

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OVHAUL
ACC
Step Service Action P/PM
TST
offline
As default, perform the shaft rotation test
with uncoupled motor and energize the
motor to verify the shaft rotation. If above
test is not possible or practical, use the
Phase Rotation
Test as described per G7M-0010-17.This
tester will indicate the direction of
rotation of the motor without
energization.!
Do not connect the Phase Rotation


Meter to a power source.

4 FUNTES
Do not confuse this tester with the Phase
Sequence Meter which verifies the phase
sequence of the 50 or 60-cycle AC power
system.

E061J


E061K


E061L


E061M 

E061N

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OVHAUL
ACC
Step Service Action P/PM
TST
offline
Dielectric Absorption (DA) ratio and
Polarization Index (PI) test as per G7M-
0010-02.
The DA test is performed with a megger


and is the 60 second reading divided by

the insulation measured at 30 seconds
after the start of the test.
Poor ........< 1.1
Questionable 1.1 to 1.25
Fair ....... 1.25 to 1.40
Large motors
Good ....... 1.40 to 1.60
 

E061J
 

E061K
 

E061L
 

 

E061M
E061N

The PI test is performed with a megger



5 PITEST
and is the 10 minute reading divided by
the insulation measured at the 1 minute
reading..
Dangerous ....... < 1.0
Poor ............ < 1.5
Questionable...1.5 to 2.0
Fair ......... 2.0 to 3.00

Note that it may be difficult to get a

meaningful dielectric absorption quantity for
recent insulation systems when the insulation
is in excellent condition. If the one minute
reading is above 5000 megohms, the ratio
value may be disregarded.

E061J
 

 

E061K  

E061L  

E061M  

E061N

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OVHAUL
ACC
Step Service Action P/PM
TST
offline
Perform High Potential test on as per G7M-
0010-04.
North America: DC Acceptance test voltage
= [(2xE) +1000] x 1.7 x 0.75
North America: DC Maintenance test voltage
= [(2xE) + 1000] x 1.7 x 0.65
North America: AC Acceptance test voltage
= [(2xE) +1000] x 0.75
North America: AC Maintenance test voltage
= [(2xE) + 1000] x 0.65
7 HIPOT
IEC: AC Acceptance test voltage =
[(2xUn) + 1000] x 0.75
IEC: AC Maintenance test voltage =
[(2xUn) + 1000] x 0.65
E061J
 

E061K


E061L


E061M


E061N


Perform a Dissipation/Power Factor Test as

per G7M-0010-05. Indicates the tangent of
the complement of the angle between the
applied voltage and the resultant current.

8 PWRFCT E061J
 

E061K
 

E061L
 

 

E061M  

E061N

Check continuity and accuracy of resistance

temperature detectors (RTD’s). Use a 50 volt
megger to test RTD’s. At 25 (+/- 5) degrees
Celsius min resistance = 100Mohm
RTDTST
9 E061J


E061K


E061L


E061M


E061N

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OVHAUL
ACC
Step Service Action P/PM
TST
offline
Perform an AC pole drop test on all stator
windings.

E061J


ACPDTST
10 E061K


E061L


E061M 

E061N

Current Transformer Saturation Test as per

G7M-0010-14. Compare the curve in the
knee obtained to the manufacturers
published curves. Any deviation should be
investigated.
CTTST
11
E061J
 

E061K


E061L


E061M 

E061N

Current Transformer Ratio Test as per G7M-

0010-23. Inject and record primary current
into the CT and divided by the secondary
current flow.
CTTST E061J
 

12
E061K


E061L


E061M 

E061N

Prior to start-up, verify operation of control

functions as suggested by the manufacturer
and according to one-line diagrams

E061J


13 FUNTES
E061K


E061L


E061M 

E061N

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OVHAUL
ACC
Step Service Action P/PM
TST
offline
Before initial start-up, apply system voltage
to the exciter, adjust exciter field current to
nameplate, and test the motor starter.

E061J


14 FUNTES
E061K


E061L


E061M 

E061N

Perform current spectrum analysis. This test

requires special CT’s, data gathering and
software for analysis. It could detect broken
rotor bars, rotor eccentricy, shorted turns and
other items. This test will have to be
outsource to a supplier specializing in this
test. This test is only to be used for motors
with poor reliability and unknown source of
15
CUSPAN trouble.
E061J
 

E061K
 

 

E061L  

E061M  

E061N

Perform Partial Discharge (PD) testing. This

test requires special sensors, data gathering
and software for analysis. It can detect
corona, loose wedges, insulation
voids/delaminating and ground wall
insulation degradation. This test will have to
be outsourced to a supplier specializing in
this test.
16
PDTST All machines 11Kv and above installed
after 01/01/02
E061J
 

E061K
 

 

E061L  

E061M  

E061N

Note: Various tests will normally support the same conclusion. When evaluating generators or motors,
more than one test should support any corrective action.

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Functional
Follow the steps below to perform functional tests and to confirm proper lubrication
Tests and
on the equipment.
Lubrication

OVHAUL
ACC
Step Service Action P/PM
TST
offline
Check and lubricate bearings as per site
lubrication frequency schedule.
E061J
 

E061K
 

1 LUBAF
E061L
 

 

E061M  

E061N

Check oil level as per site lubrication

frequency schedule.
E061J
 

E061K
 

2 LUBCK
E061L
 

 

E061M  

E061N

Check condition of lubricating oil for

contamination and impurities by R&D or
authorized laboratory.
E061J
 

iii
3 LUBCD E061K
 

E061L
 

 

E061M  

E061N

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OVHAUL
ACC
Step Service Action P/PM
TST
offline
Perform vibration analysis test after each
overhaul and on routine basis as described
by the Condition Based Electrical PPM web
site.
NEMA & IEC: (G7D-0613-00)
< 0.08 in/sec or 2.0 mm/sec
Large motors <700 hp
(G7D-0661-00)
Radial - 0.1 in/sec or 2.54 mm/sec
Axial - .08 in/sec peak or 2.0 mm/sec
Filtered Vib @ 120Hz .05 in/sec peak
Large motors > 700 hp
4 SCHVIB
(G7D-0662-00), Synchronous motor &
Generators AC
Unfilter Filter Filter
2x rpm 2x LF
An Frict brgs. 0.1 0.05 0.05
Sleeve brgs 0.08 0.05 0.05  

E061J  

E061K  

E061L  

E061M  

E061N

Verify motor full load current with nameplate

value.
E061J


E061K


5 AMPTST 

E061L


E061M 

E061N

Function test all alarm systems associated

with the motor to confirm proper operation.
E061J
 

E061K
 

6 ALMTST
E061L
 

E061M
 

 

E061N

Inspect and clean brush support mechanism,

spring tension test and replace brushes as
required.
E061J
 

E061K
 

7 BRUSH
E061L
 

 

E061M  

E061N

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OVHAUL
ACC
Step Service Action P/PM
TST
offline
Perform complete function test on the
excitation systems include tuning or upper
and lower exciter limiters, regulators, etc.
E061J


E061K


8 EXCSCK


E061L


E061M 

E061N

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Return to Operation Follow the steps below to return the equipment to operation.

Step Service Action OVHAUL ACC

P/PM TST
offline
After testing is complete, visually inspect for
the following items:
1. Couplings attached as required
2. All disconnected leads reconnected
3. All other items compromised during
testing have been returned to their
original state prior to releasing back to
1 PREP owner.
4. Safety grounds installed during testing
have been removed.
5. All fuses replaced
6. All appropriate red tags removed
7. Refer to appropriate start- up procedures
 

All Motors
New or overhauled motors shall be properly
preferably stored in a vibration free climate
controlled area. When this is not possible
and the equipment has space heaters, the
2 PREP
space heaters shall be connected to a power
source.
 

All Motors

Large motors should have their shafts

rotated on a regular basis when in storage.
3 PREP
All Motors

Define the overall equipment condition index

numbers (1-4) according to descriptions in
the Global Electrical Safety and Reliability
4 PREP
Audit G7A-0060-00.

All Motors
 

All test forms and data sheets are to be

submitted to the appropriate authority for
5 PREP entry into GEMTS and in the ODMS library if
applicable.  

All Motors

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i
01-OCT-2003,MOC2003_0600_108,By:Rudy Vervaet, Supercedes Issue Date 24-SEP-
2003, The revised practice was changed/updated as a result of
review/synchronization between the Condition Based PPM web site and the G7M
PPM practices.
ii
05-NOV-2004, MOC 2004_02335, By: Rudy Vervaet, Supercedes Issue Date 01-
OCT-2003, Updated the equipment codes to the new CBE tool
iii
13-SEP-2005, MOC 2005_03091, By: Rudy Vervaet, Supercedes Issue Date 05-
NOC-2004, At FUNCTIONAL TEST & LUBRICATION, STEP 3 changed IOLANL to LUBCD.

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