(HUMAN RESOURSE DEVELOPMENT CENTER )

A TRAINING REPORT ON (LEM)

SUBMITTED TO
B.H.E.L
(BHARAT HEAVY ELECTRICAL LIMITED)

IN PARTIAL FULFILLMENT OF REQUIREMENT FOR THE

DEGREE OF BACHELOR OF TECHNOLOGY ( B.Tech )
(ELECTRICAL ENGINEERING )

SUBMITTED BY :- UNDER THE GUIDANCE OF

YASIR ULLAH KHAN, MR. K. K. SASMEL
(ELECTRICAL ENGINEERING) SENIOR ENGINEER
MAULANA AZAD NATIONAL INSTITUTE
OF TECHNOLOGY,BHOPAL.
 ( HUMAN RESOURSE DEVELOPMENT CENTER )
A TRAINING REPORT ON (LEM)
SUBMITTED TO
B.H.E.L
( BHARAT HEAVY ELECTRICAL LIMITED )

DECLARATION
I hereby declare that the work presented in this winter training entitled on
“LEM” is in partial fulfillment for the awarded of degree of bachelor of
engineering in Electrical Engineering. The work has been carried out at
B.H.E.L., Bhopal and is an authentic record of own work.
We hereby declare that above statement is correct to the best of
my knowledge.
BHOPAL- YASIR
ULLAH KHAN
Date- 19th DECEMBER 2018 TOKEN
NO:VT/2018/3192
 B.H.E.L
( BHARAT HEAVY ELECTRICALS LIMITED )

CERTIFICATE
This is to certify that the work embodied in this project work entitled “LEM”
has been satisfactorily completed by YASIR ULLAH KHAN. It is a
bonafide piece of work, carried out under the guidance of H.R.D.C.
B.H.E.L , BHOPAL by the student during the period of December 2018
under the guidance of undersigned

UNDER THE GUIDANCE OF

MR. K.K. SASMEL
SR. ENGINEER (LEM)
ACKNOWLEDGEMENT
I would like to express my special thanks of gratitude to Mr. K.K. SASMEL
(training coordinator) for providing me this golden opportunity to work as
trainee in the highly renowned company “BHARAT HEAVY
ELECTRICALS LIMITED”.
I would also like to thank all the engineers and employees of the LEM
department who have managed to extract some of their precious time in
explaining the technicalities and features of their respective sections of
department.
I would also like to sincerely appreciate the efforts of Er. RUPESH sir, who
helped me a lot in knowing the complexities and the technical stuff of
machine used here.
I would also like to thank my friends and fellow trainee who contributed to
the useful discussion in the plant. These 2 weeks in BHEL have certainly
raised my knowledge to a new level.
 About BHEL- THE MAHARATNA

BHEL was established in 1964 ushering in the indigenous Heavy Electrical

Equipment industry in India. Heavy Electricals (India) Limited was merged
with BHEL in 1974. In 1991, BHEL was converted into a public limited
company. Over time, it developed the capability to produce a variety of
electrical, electronic and mechanical equipments for all sectors, including
transmission, transportation, oil and gas and other allied industries. However,
the bulk of the revenue of the company is derived from sale of equipment for
power generation such as turbines, boilers, etc. As of 2017, BHEL supplied
equipment contributed to about 55% of the total installed power generation
capacity of India. The company has also supplied thousands of Electric
Locomotives to Indian Railway, as well as defence equipment such as the
Super Rapid Gun Mount (SRGM) naval guns and Defence Simulators to the
Indian Armed Forces.

BHEL caters to the core sectors of the Indian Economy, viz. Power,
Transmission, Industry, Transportation, Renewable Energy, Oil & Gas and
Defence. The wide network of BHEL’s 15 Manufacturing Divisions, 4
Power Sector Regional Centers, 8 Service Centers, 15 Regional Offices, 4
Overseas Offices, 1 Subsidiary and over 100 project sites spread all over
India enables the Company to promptly serve its customers and provide
them with suitable products, systems and services -- efficiently and at
competitive prices. The high level of quality & reliability of its products is
due to the emphasis on design, engineering and manufacturing to
international standards by acquiring and adapting some of the best
technologies from leading companies in the world, together with
technologies developed in its own R&D centres.

BHEL has acquired certifications to Quality Management Systems (ISO

9001), Environmental Management Systems (ISO 14001) and Occupational
Health & Safety Management Systems (OHSAS 18001) and is also well on
its journey towards Total Quality Management

BHEL has

Installed equipment for over 1,00,000 MW of power generation- for

Utilities, Captive and Industrial users.

Supplied over 2,25,000 MVA transformer capacity and other equipment

operating in Transmission & Distribution network up to 400 kV (AC &
DC).

Supplied over 25,000 Motors with Drive Control System to Power

projects, Petrochemicals, Refineries, Steel, Aluminum, Fertilizer, Cement
plants, etc.

Supplied Traction electrics and AC/DC locos to power over 12,000 kms
Railway network.

Supplied over one million Valves to Power Plants and other Industries.

BHEL's operations are organised around three business sectors, namely

Power, Industry - including Transmission, Transportation and Renewable
Energy - and Overseas Business. This enables BHEL to have a strong
customer orientation, to be sensitive to his needs and respond quickly to the
changes in the market.
BHEL's vision is to become a world-class engineering enterprise,
committed to enhancing stakeholder value. The company is striving to give
shape to its aspirations and fulfill the expectations of the country to become
a global player.

The greatest strength of BHEL is its highly skilled and committed team of
46,748 employees. Every employee is given an equal opportunity to
develop himself and grow in his career. Continuous training and retraining,
career planning, a positive work culture and participative style of
management have engendered development of a committed and motivated
workforce setting new benchmarks in terms of productivity, quality and
responsiveness.
INTRODUCTION ABOUT BHEL
BHOPAL PLANT
 BHEL Bhopal is the mother unit of BHEL
 This plant is divided into 15 manufacturing units with 18 R.O.Ds
 BHEL in all supplies it products to about 70 countries round the globe
 The plant can be divided in the following sub-sections
i. STM (Steam Turbine Manufacturing Unit)
ii. HCM ( Heat and Condensers Manufacturing unit)
iii. WTM (Water Turbine Manufacturing unit)
iv. EMM (Electric Motor Manufacturing unit)
v. IMM (Induction Motor Manufacturing unit)
vi. MOD ( Modernization)
vii. TXM ( Traction Motor Manufacturing unit)
viii. TAM (Tata Auxiliary Machines)
ix. TCB (Transformer, Capacitor and Bushing)
x. SCR ( Switch gears, Control gears and Rectifiers)
xi. CIM ( Commutators, Insulation Manufacturing)
xii. PRM ( Press Off Machining)
xiii. UHV (Ultra High Voltage Lab)
xiv. New Transformer Block
xv. New Hydro Block

PRODUCTS AT BHEL:
1. HYDRAULIC TURBINES
2. STEAM TURBINES
3. Heat and Condensers
4. Electric Motors
5. Induction Motors
6. Traction Motors
7. Transformers, Capacitors and Bushings
 8. Switch gears, Control gears and Rectifiers
9. Com mutator
10. Insulation
11. Railway wagon

LEM (LARGE ELECTRICAL MACHINES)

- Table of contents

- Induction motor

- Synchronous Motor

- Coil Housing

- Slot wedging

- Brazing

- VPI
 - Testings

- Dispatching

INDUCTION MOTOR
An induction motor or asynchronous motor is a type of alternating current
motor where power is supplied to the rotor by means of electromagnetic
induction.

An induction motor is sometimes called a rotating transformer because the

stator (stationary part) is essentially the primary side of the transformer and
the rotor (rotating part) is the secondary side. Unlike the normal transformer
that changes the current by using time varying flux, induction motors use
rotating magnetic fields to transform the voltage. The current in the primary
side creates an electromagnetic field which interacts with the
electromagnetic field of the secondary side to produce a resultant torque,
thereby transforming the electrical energy into mechanical energy. Induction
motors are widely used, especially polyphase induction motors, which are
frequently used in industrial drives.

Induction motors are now the preferred choice for industrial motors due to
their rugged construction, absence of brushes (which are required in most
DC motors) and—thanks to modern power electronics—the ability to
control the speed of the motor.
Synchronous speed
To understand the behaviour of induction motors, it is useful to understand
their distinction from a synchronous motor. A synchronous motor always
runs at a synchronous speed- a shaft rotation frequency that is an integer
fraction of the supply frequency. The synchronous speed of an induction
motor is the same fraction of the supply.

It can be shown that the synchronous speed of a motor is determined by the

following formula:

where ns is the (synchronous) speed of the rotor (in rpm), f is the frequency
of the AC supply (in Hz) and p is the number of magnetic poles per phase.

For example, a 6 pole motor operating on 50 Hz power would have a speed

of:
Note on the use of p - some texts refer to number of pole pairs per phase
instead of number of poles per phase. For example a 6 pole motor, operating
on 60 Hz power, would have 3 pole pairs. The equation of synchronous
speed then becomes:

with P being the number of pole pairs per phase.

Slip

typical torque curve as a function of slip

The slip is a ratio relative to the synchronous speed and is calculated usi.

ng:

Where

s is the slip, usually between 0 and 1

nr = rotor rotation speed (rpm)
ns = synchronous rotation speed (rpm)
Construction

A three phase Induction motor mainly consists of two parts called as

the Stator and the Rotor. The stator is the stationary part of the induction
motor, and the rotor is the rotating part. The construction of the stator is
similar to the three-phase synchronous motor, and the construction of rotor is
different for the different machine. The construction of the induction motor
is explained below in detail.

Construction of Stator
The stator is built up of high-grade alloy steel laminations to reduce eddy
current losses. It has three main parts, namely outer frame, the stator core
and a stator winding.

Outer frame
It is the outer body of the motor. Its main function is to support the stator
core and to protect the inner parts of the machine. For small machines, the
outer frame is casted, but for the large machine, it is fabricated. The figure
below shows the stator construction.
Stator Core
The stator core is built of high-grade silicon steel stampings of CRNGO
material. Its main function is to carry the alternating magnetic field which
produces hysteresis and eddy current losses. The stampings are fixed to the
stator frame. Each stamping are insulated from the other with a thin varnish
layer. The thickness of the stamping usually varies from 0.3 to 0.5 mm. Slots
are punched on the inner side of the stampings as shown in the figure below.
COMPARISON BETWEEN CRGO & CRNGO

CRGO & CRNGO are both electrical steel grades used for
stampings & cores of electrical Transformers & other
electrical appliances.
CRNGO is cold rolled Non Grain Oriented steel laminations
thickness available is not less than .50mm as compared
to .27 of CRGO, & Hence the losses in CRNGO are more than
four times of CRGO.
CRNGO Non oriented fully processed steels are iron-silicon alloys with
varying silicon contents and have similar magnetic properties in all
directions in the plan of the sheet. They are principally
used for motors, generators, alternators, ballasts, small
transformers and a variety of other electromagnetic
applications.
WHERE AS CRGO is used for Distribution as well as Power
Transformers due to its low loss characteristics.
Cold rolled provides the lamination to steel which decrease the eddy current
losses and Grain oriented process increases the magnetic property of steel.
CRGO or Cold Rolled Grain Oriented Steel is available in
various grades (generally called M3, M4, M5 & M6). Major
international standards such as Japanese (JIS), American
(ASTM), German (DIN) and British Standards are AVAILABLE
which specify grade, thickness, Watt Losses and Magnetic
Flux density.Conventional CRGO materials (M4, M5, M6) are
used regularly for cores in Transformers.

Stator windings
The core of the stator carries three phase windings which are usually
supplied from a three-phase supply system. The six terminals of the
windings (two of each phase) are connected in the terminal box of the
machine. The stator of the motor is wound for a definite number of poles,
depending on the speed of the motor. If the number of poles is greater, the
speed of the motor will be less and if the number of poles is less than the
speed will be high.

As the relationship between the speed and the pole of the motor is given as
 The windings may be connected in start and delta.

Construction of Rotor
The rotor is also built of thin laminations of the same material as the stator.
The laminated cylindrical core is mounted directly on the shaft. These
laminations are slotted on the outer side to receive the conductors. There are
two types of rotor.

Squirrel Cage Rotor

A squirrel cage rotor consists of a laminated cylindrical core. The circular
slots at the outer periphery are semi-closed. Each slot contains uninsulated
bar conductor of aluminium or copper. At the end of the rotor the conductors
the short-circuited by a heavy ring of copper or aluminium. The diagram of
the cage rotor is shown below.

The rotor slots are usually not parallel to the shaft but are skewed. The
skewing of the rotor conductors has the following advantages given below.

 It reduces humming and provide smooth and noise free operation.

 It results in a uniform torque curve for different positions of the rotor.
 The locking tendency of the rotor is reduced. As the teeth of the rotor
and the stator attract each other and lock.
 It increases the rotor resistance due to the increased length of the rotor
bar conductors.

Advantages of Squirrel Cage Rotor

The following advantages of the cage rotor are given below.

 The cage rotor is cheaper, and the construction is robust.

 The absence of the brushes reduces the risk of sparking.
 Its Maintenance is less.
 The power factor is higher
 The efficiency of the cage rotor is higher.

Phase Wound Rotor

The Phase wound rotor is also called as Slip Ring Rotor. It consists of a
cylindrical core which is laminated. The outer periphery of the rotor has a
semi-closed slot which carries a 3 phase insulated windings. The rotor
windings are connected in star.

The slip ring induction motor is shown in the figure below.

The slip rings are mounted on the shaft with brushes resting on them. The
brushes are connected to the variable resistor. The function of the slip rings
and the brushes is to provide a means of connecting external resistors in the
rotor circuit. The resistor enables the variation of each rotor phase resistance
to serve the following purposes given below.
 It increases the starting torque and decreases the starting current.
 It is used to control the speed of the motor.

In this type also, the rotor is skewed. A mild steel shaft is passed through the
center of the rotor and is fixed to it. The purpose of the shaft is to transfer
mechanical power.

Advantages of Phase Wound Rotor

Following are the advantages of the Phase Wound Rotor.

 High starting torque and low starting current.

 For controlling the speed of the motor, an external resistance can
added in the circuit.

SYNCHRONOUS MOTOR
A synchronous electric motor is an AC motor distinguished by a rotor
spinning with coils passing magnets at the same rate as the power supply
frequency and resulting rotating magnetic field which drives it.

Another way of saying this is that it does not rely on slip under usual
operating conditions and as a result, produces torque at synchronous speed.
Synchronous motors can be contrasted with an induction motor, which must
slip in order to produce torque. They operate synchronously with line
frequency. As with squirrel-cage induction motors, speed is determined by
the number of pairs of poles and the line frequency.

Synchronous motors are available in sub-fractional self-excited sizes to

high-horsepower direct-current excited industrial sizes. In the fractional
horsepower range, most synchronous motors are used where precise constant
speed is required. In high-horsepower industrial sizes, the synchronous
motor provides two important functions. First, it is a highly efficient means
of converting ac energy to work. Second, it can operate at leading or unity
power factor and thereby provide power-factor correction.
There are two major types of synchronous motors: 'non-excited' and 'direct-
current excited', which have no self-starting capability to reach synchronism
without extra excitation means, such as electronic control or induction.

Synchronous speed
The "synchronous speed" of a synchronous motor is determined by the
following formula:

where v is the speed of the rotor (in rpm), f is the frequency of the AC supply
(in Hz) and n is the number of magnetic poles. Different from all other
synchronous motors, the synchronous brushless wound-rotor doubly-fed
electric machine operates from sub-synchronous to super-synchronous
speeds or twice synchronous speed.

Parts
A synchronous motor is composed of the following parts:

 The stator is the outer shell of the motor, which carries the armature
winding. This winding is spatially distributed for poly-phase AC
current. This armature creates a rotating magnetic field inside the
motor.
 The rotor is the rotating portion of the motor. It carries field winding,
which may be supplied by a DC source. On excitation, this field
winding behaves as a permanent magnet.Some machines use
permanent magnets in the rotor.
 The slip rings on the rotor, to supply the DC to the field winding.
 The stator frame contains and supports the other parts and may
include bearing housings.

Large machines may include additional parts for cooling the machine,
supporting the rotor, lubricating and cooling the bearings, and various
protection and measurement devices.
Operation
The operation of a synchronous motor is simple to imagine. The armature
winding, when excited by a poly-phase (usually 3-phase) supply, creates a
rotating magnetic field inside the motor. The field winding, which acts as a
permanent magnet, simply locks in with the rotating magnetic field and
rotates along with it. During operation, as the field locks in with the rotating
magnetic field, the motor is said to be in synchronization.

Once the motor is in operation, the speed of the motor is dependent only on
the supply frequency. When the motor load is increased beyond the break
down load, the motor falls out of synchronization i.e., the applied load is
large enough to pull out the field winding from following the rotating
magnetic field. The motor immediately stalls after it falls out of
synchronization.

Special Properties
Synchronous motors show some interesting properties, which finds
applications in power factor correction. The synchronous motor can be run
at lagging, unity or leading power factor. The control is with the field
excitation, as described below:

 When the field excitation voltage is decreased, the motor runs in

lagging power factor. The power factor by which the motor lags varies
directly with the drop in excitation voltage. This condition is called
under-excitation.
 When the field excitation voltage is made equal to the rated voltage,
the motor runs at unity power factor.
 When the field excitation voltage is increased above the rated voltage,
the motor runs at leading power factor. And the power factor by which
the motor leads varies directly with the increase in field excitation
voltage. This condition is called over-excitation.
  The most basic property of synchro motor is that it can be used both
as a capacitor or inductor. Hence in turn it improves the power factor
of system.

The leading power factor operation of synchronous motor finds application

in power factor correction. Normally, all the loads connected to the power
supply grid run in lagging power factor, which increases reactive power
consumption in the grid, thus contributing to additional losses. In such cases,
a synchronous motor with no load is connected to the grid and is run over-
excited, so that the leading power factor created by synchronous motor
compensates the existing lagging power factor in the grid and the overall
power factor is brought close to 1 (unity power factor). If unity power factor
is maintained in a grid, reactive power losses diminish to zero, increasing the
efficiency of the grid. This operation of synchronous motor in over-excited
mode to correct the power factor is sometimes called as Synchronous
condenser.
Uses
 Synchronous motors find applications in all industrial applications
where constant speed is necessary.
 Improving the power factor as synchronous condensers.
 Low power applications include positioning machines, where high
precision is required, and robot actuators.
 Mains synchronous motors are used for electric clocks.
 Record player turntables

Advantages
Synchronous motors have the following advantages over non-synchronous
motors:

 Speed is independent of the load, provided an adequate field current is

applied.
 Accurate control in speed and position using open loop controls, eg.
stepper motors.
 They will hold their position when a DC current is applied to both the
stator and the rotor windings.
 Their power factor can be adjusted to unity by using a proper field
current relative to the load. Also, a "capacitive" power factor, (current
 phase leads voltage phase), can be obtained by increasing this current
slightly, which can help achieve a better power factor correction for
the whole installation.
 Their construction allows for increased electrical efficiency when a
low speed is required (as in ball mills and similar apparatus).
 They run either at the synchronous speed or they do not run at all.

1) Coil Housings

National Electrical Equipment Manufacturers Association

defines the various types of electrical enclosures used as
follows:
NEMA 1 enclosures are intended for indoor use primarily to
provide a degree of protection against contact with the
enclosed equipment in locations where unusual service
conditions do not exist. They provide a degree of protection
against limited amounts of falling dirt but will not prevent
the entry of dust or liquids. They prevent the insertion of a
straight rod of a specified diameter into the equipment
cavity of the enclosure.
NEMA 4 enclosures are intended for indoor or outdoor use
primarily to provide a degree of protection against
windblown dust and rain, splashing water, and hose directed
water.
NEMA 7 enclosures are used in hazardous locations and are
designed to contain an internal explosion without causing an
external hazard. Type 7 enclosures are intended for indoor
use and are capable of withstanding the pressures resulting
from an internal explosion of specified gasses and contain
such an explosion sufficiently that an explosive gas-air
mixture existing in the atmosphere surrounding the
enclosure will not be ignited. In operation, external surfaces
do not reach temperatures capable of igniting explosive gas-
air mixtures in the surrounding atmosphere.
NEMA 9 enclosures prevent the entrance of dust and
external surfaces do not reach temperatures capable of
igniting explosive dust-air mixtures in the surrounding
atmosphere. Type 9 enclosures are intended for indoor
usage.

Slot wedges made of magnetic material are a significant means to improve

the efficiency of a motor or generator. Magnetic slot wedges reduce slot
ripple in the air gap flux caused by the changing reluctance due to the slots,
and also reduce the associated eddy current losses due to the interaction of
the harmonics in the air gap flux with the conducting surface of the rotor.

The magnetizing current required in the stator windings to generate the

desired air gap flux is less with magnetic slot wedges, since more of the air
gap flux is available for useful power production.

Magnetic slot wedges reduce starting current, improve cos phi and load
current, and lead to reduced iron loss (core loss).

Typical reduction of iron loss is in the range of some kW depending on the

type of machine. This means a corresponding
value of some thousand Euros, when calculating the machine prize. So it is
obvious that additional costs for high performance
slot wedges clearly pay off.

2) Brazing
Brazing is a heating process in which copper, brass or steel materials are
joined together by means of another metal alloy with a lower melting point.
Braze joints can be made exceptionally strong, sometimes stronger than the
two metals being joined. (The term 'silver soldering' is sometimes used to
refer to silver brazing.)

Braze joints are liquid- and gas-tight, can withstand shock and vibration, are
unaffected by normal temperature changes, provide good electrical
conductivity and can be easily plated using conventional processes. Typical
brazing temperatures vary between 800°F and 2150° F.

SALIENT FEATURES
Uniform heating at desired area provides even flow of filler metal
Lesser brazing cost comparing to conventional methods.
Strong and ductile joints
Suitable for dissimilar materials
Controlled atmosphere brazing is possible
Highly adaptable for automation
Eco-friendly due to noiseless and flameless operation
No statutory approvals required
Lesser risk involved compared to conventional methods
Application Specific
Auto or manual mode operation
Improved power factor.
Tropicalised design
Compact size.
Vacuum Pressure Impregnation Processing

The VPI process provides many benefits to the user. it completely

seals the windings against moisture and vibration, provides greater
mechanical strength, and improved corona protection.

it vastly improves performance and reliability even in the hardest

working environments. machines last longer and require less
maintenance. VPI is a process, which provides positive payback over
a short period of time.

Goltens has the biggest VPI plant operating in the region. The plant is
3m diameter x 3m depth.

The equipment is designed to process the broadest range of

products, from small AC/DC could upto 11 KV machines

Plant Specification

Hydraulic / Pneumatic Control System

Operation Voltage 3 x 380 VAC, 50 hz
Dimensions of Impregnation tank 3m diameter x 3m depth
Impregnated media maximum capacity Approx. 10,000 liters
Compressed air working pressure Max. 6 Bar
Manufactured in Spain
System CE Standard
Vacuum capacity up to -0.99 Bar

The VPI system is used after the motor stator has been
renowned to guarantee reliability and consistency. The three
step process works as follows:

 The stator is suspended in a sealed tank, creating a vacuum.

 A transfer valve is opened and the appropriate medium
(varnish/ resin) is transferred from a storage tank into the
processing tank until the stator windings are completely
immersed.

 The transfer valve is then closed and the tank is held under
vacuum for a period of time before being pressurized to force
the medium through the multiple layers of wire and insulation
(filling all voids)

Testing Facility
 Testing facility providing from 0 to 11kV (variable), 3 MW
capacity
 Testing facility for bearing temperature monitoring
 Testing facility for vibration analyzing
 Insulation resistance tester up to 37KV
 Winding resistance test in Millie ohms
 Hot spot test of stator core
 Phase comparison test after rewinding
 Test equipment to test coils for internal insulation leakage
 test equipment to test rotor for internal cracks / condition
 In-house facility of rebabbitting of white metal bearing &
machining
 In-house facility of dynamic balance up to 8 tons
 All kinds of lathe machines, boring machines and milling
machines work in house
 TESTINGS

The following are some important electric motor testing items:

Electric Motor Testing Recommended Items:

Electric Motor Impulse Testing

Electric Motor impulse testing is an integral part of predictive maintenance
of electrical motors. Through the following questions the influence that
extensive impulse testing has on a motor is investigated. Can impulse testing
damage healthy or deteriorated insulation? Can DC Resistance, Inductance,
Megger or HiPot tests diagnose weak turn-to-turn insulation? After failing
an impulse test, are motor with weak insulation able to operate? Are motors
with a turn-turn short capable of continued operation? This was
accomplished by putting a low voltage motor through extensive testing
rigors, until inducing a failure. Following the failure, additional testing
investigated the possible deteriorating effects on turn-turn insulation due to
impulse testing beyond the motor’s dielectric breakdown. NOTE: This paper
was edited from the original version of the IEEE paper published in 2003.

Electric Motor Rotation Testing

Check for fan or pump motor rotation when testing offline with the MCE.
Fans may continue to slowly rotate due to drafting in the Plenum. Pumps
that are connected to a common header may continue to rotate if other
pumps connected to the header are operating. This will adversely affect the
Standard Test results, possibly creating higher than normal resistive and
inductive imbalances.

Wound Rotor Motor Testing

Wound rotor motors have a three-phase winding wound on the rotor which is
connected to three phases of start-up resistors in order to provide current and
speed control on start-up. Failed components in the resistor bank are
common and often overlooked when troubleshooting. These faults can have
a significant impact on the overall operation of the motor and should be
given considerable focus when troubleshooting these motors.
Electric Motor Insulation Resistance Testing
Electric motor insulation exhibits a negative temperature coefficient,
meaning as temperature increases, resistance decreases. This would lead you
to believe that insulation resistance of a de-energized motor will decrease
after starting the motor. However, most often the resistance will initially
increase after running due to moisture being evaporated by the increasing
temperature of the windings. The governing standard (IEEE43) on insulation
resistance testing requires a temperature correction to 40 degrees Celsius,
which could quickly turn acceptable measured resistance readings into
unacceptably low corrected resistance readings. Before sending a motor to
be refurbished, consider space heaters.

The recommended off-line in-service electric motor tests are -

 Stator winding resistive imbalance

 Stator winding insulation resistance (Meg-Ohm checks)
 Polarization Index (PI)
 Step Voltage test
 Surge test

The recommended spare electric motor tests are -

 Stator winding resistive imbalance

 Stator winding insulation resistance (Meg-Ohm checks)
 Polarization Index (PI)
 Step Voltage test
 Surge test

The recommended new/refurbished electric motor tests are –

 Stator winding resistive imbalance

 Stator winding insulation resistance (Meg-Ohm checks)
 Polarization Index (PI)
 Step Voltage test
 Surge test.