90kW Motor Routine Inspection Check-List

List of the names of Routine Tests (as per applicable code IS 325), in sequence therein:
a) Insulation Resistance Test
b) Measurement of resistance of windings of stator & wound rotor (hope, present case is squirrel
cage rotor; so, no wound rotor)
c) No-load test
d) Locked rotor test (In locked rotor condition, readings of voltage, current & power input, at a
suitably reduced voltage)
e) High Voltage test
f) Dimensions (though not indicated under Routine Test in code, norm is to check w.r.t. approved
GA drawings)
g) Test for vibration (not under Routine Test in code, but as per prevailing norms)
h) Test for noise level(not under Routine Test in code, but as per prevailing norms)
Procedure:
1)

First, the motor will be identified. Then, to check whether motor name plate is already fixed.
Then, name plate details to be checked w.r.t. approved data sheet. If anything does not tally,
the same to be noted in Joint Inspection Report.

2)

Insulation Resistance to be tested (by megger hand-driven, or, motorized) between each
phase-winding terminal in turn & frame/earth of the motor, with other phases shorted to
earth. To do this, delta-connecting links may have to be removed first. If motorized megger
is available, PI (polarization index) may be taken by taking reading of megger after one
minute & after ten minutes. Megger test may be done both before & after HV test.

3)

Measurement of resistance to be done each time across two of the three terminals U1, V1,
W1 in motor terminal box (main). So, three readings to be taken. Delta shorting links may
remain. Surrounding temperature is also to be recorded by a suitable thermometer at the
inspection place.

4)

No-load test Motor is to be run at no-load (no shaft coupling) at rated voltage & rated
frequency, for a considerable time until watt input becomes steady. Then, readings of
voltage, current, frequency & power input and speed shall be noted. Speed will be measured
not by a tachometer, but by a stroboscope meter.

5)

Locked rotor test the manufacturer will block the rotation of the rotor by a suitable hard
rod-like thing, after carefully observing the rotation during previous test. Then, slowly
voltage will be applied and raised till current is equal to rated current. Then, again, readings
of voltage, frequency, current & power input to be noted.

6)

High voltage test If the motor is rated at 415V, HV test voltage shall be
2x415+1000=1830V, only if, there has been no prior testing before inviting inspection. But,
if they have tested in-house, before sending inspection call, 80% of that voltage will be
applied, i.e., 1460V.

7)

Dimensions will have to taken for the dimensions indicated in the GA drawing.

8)

Vibration levels to be measured both at driving end (DE) & non-driving end (NDE).
Measurement points shall be horizontal, vertical & axial on the shaft. Sometimes, at NDE,
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axial measurement will not be accessible. Then, only others to be taken. Also, sometimes,
due to cowl (big cover at NDE). Then, measurement on the cowl itself to be taken.
9)

Noise Measurement is to be taken with the help of a decibel meter, around motor during
no-load test, one metre distant from the motor; and also, background noise at the same
points when motor is not running. Points of measurement will be at two ends axially,
laterally both side, and top, if the motor is presumably B3 (horizontal) mounting. So, five
points minimum at key measuring points, as per IS code. Plus other points may be taken.
To remember that each location will have two values one with motor running, other not
running.

Sequence:
1)
2)
3)
4)
5)
6)
7)
8)

Name plate checking

Dimension & other visual checking w.r.t. GA drawing
Insulation Resistance before HV test
HV Test
Insulation Resistance after HV test
Winding Resistance
No-load test with vibration & noise test
Blocked Rotor test

Requirement of documents:
1)
2)
3)

Approved (Stamped) Data Sheet

Approved GA Drawing(s)
Prior works test report, if any

(Normally, manufacturers have standard formats. So, these test data are only to be put on that sheet)

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