NO.

530-U07-00306

REV. 0
STANDARD TEST AND COMMISSIONING PROCEDURE
PAGE 1 of 11
EFFECTIVE: February ,2011

MOTOR RUN TESTING

Reviewing by:
Prepared by: Approved By: Date Approved:
Abdel Maksoud Gad,
Ahmed Samir Ahmed Younes, Richard
Brawn

1.0 PURPOSE

This procedure provides a safe, standardized approach for the initial

inspection, checkout, testing, and data documentation of electric
motors used to drive rotating equipment.

2.0 SCOPE

2.1 This procedure is applicable to all PGESCo management projects

and covers all motors for which contractor has
startup/commissioning responsibility. It applies to ac and dc motors
used to drive rotating mechanical equipment. Motors used as
operators for valves, gates, dampers, etc. are not within the scope of
this procedure.

This procedure shall be implemented during initial

uncoupled/unloaded operation of applicable equipment, as well as
during the initial coupled/loaded operation. However, it may be used
at any time during equipment operation.

3.0 DEFINITIONS

Startup/Commissioning Organization – The PGESCo group are

responsible for manage the component, system, and facility testing,
cleaning, and commissioning/startup activities.

Startup/Commissioning Program – A systematic method of

transferring, testing, and commissioning components and systems.

Drive End (DE) - The end of the motor from which the shaft
protrudes and is coupled to the driven equipment. It may also be
referred to as the inboard (IB) end of the motor.

Non Drive End (NDE) - The end of the motor that is opposite the
DE. This end of the motor usually has the motor’s cooling fan
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 MOTOR RUN TESTING No. 530-U07-00306
Rev. 0
Page 2 of 11

attached. It may also be referred to as the opposite drive end (ODE)

or outboard (OB) end of the motor.

Bump - To start and immediately stop a motor from a control switch

to verify direction of rotation.

Rotation - The rotation of a motor as viewed from behind the ODE,

standing with line of sight in-line with the rotor, looking toward the
drive shaft of the driven equipment.

Magnetic Center - That position of the motor rotor where the

magnetic forces acting on the rotor are in balance during operation.
In large motors during initial run-in, the magnetic center is marked to
allow positioning of the rotor at the magnetic center for coupling
alignment. Placement of the rotor at the magnetic center assures
that no thrust from the motor is transmitted to the driven equipment
via the coupling.

Motor Doweling - A practice on some large motors where the motor

base is drilled and dowels inserted to prevent movement of the
motor. This is usually done to permanently fix the final alignment
position of the motor. In some cases the driven equipment may also
be doweled in place.

4.0 RESPONSIBILITIES

4.1 Project Startup Manager (PSUM)

Responsible for ensuring that the execution of the

Startup/Commissioning Program and ensures Startup activities are
performed in compliance with the project requirements and
procedures.

4.2 Startup Engineer

Has ultimate responsibility for coordination of all startup related

activities for his/her assigned systems.

Has responsibility for checkout witness and oversight the testing in

accordance with contract specification, codes and supplier
procedure.

4.3 Environmental Safety and Health (ES&H) Representative

Participates in and provides input to Safety Task Analysis Risk

Reduction Talk (STARRT)/Job Hazard Analysis (JHA). Provides
ES&H coverage for test activities and walk downs.

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 MOTOR RUN TESTING No. 530-U07-00306
Rev. 0
Page 3 of 11

5.0 PREREQUISITES AND SAFETY PRECAUTIONS

5.1 Prerequisites

5.1.1 Verify that test equipment used for recording data are calibrated
within their calibration interval and document on the Motor Data
Record, Exhibit B.

5.1.2 Verify that the equipment is correct (per data sheets, specifications,
etc.) and installed in accordance with project design documents and
vendor manuals/drawings. Also verify that the system installation is
complete to the extent necessary to properly support equipment
operation. Review system/component punch list.

5.1.3 Review the vendor’s instruction manual(s) for special precautions or

limitations specific to the equipment/system’s components. Note and
observe the vendor's precautions and limits, such as number of
starts, run-in duration, vibration, load, etc.

5.1.4 Verify that equipment lubrication is in accordance with the vendor's

specifications, and either a lubrication tag is attached or other docu-
mentation is verified.

5.1.5 Verify that instrumentation, controls, and alarms associated with the
equipment under test are tested, calibrated, functional, and
documented to the extent necessary to support testing.

5.1.6 Verify that the motor bearing lubrication and cooling system, if any,
is available for operation. If applicable, also verify that auxiliary
cooling fans have been checked out and are available.

5.1.7 Motors rated 250V dc or 400V ac of more than 50HP/37.5kW, and

all higher voltage motors, shall be uncoupled prior to initial start and
run-in. Motors rated less than 400V ac and less than 50HP/37.5kW
may be uncoupled at the discretion of the Startup Engineer.

5.1.8 Verify that the motor supply breaker/switchgear has been

functionally tested to ensure that it can operate with any jumpers or
lifted leads required to permit motor operation.

5.1.9 Verify that power cables are tested including space heater.

5.1.10 Verify that the protection relays and interlocks are tested for motor
circuit breaker.

5.1.11 Verify that ground cables are connected as per design drawing and
details.

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 MOTOR RUN TESTING No. 530-U07-00306
Rev. 0
Page 4 of 11

5.2 Safety Precautions

5.2.1 Areas under test must be clean and free of loose debris and only
authorized personnel are permitted in test areas.

5.2.2 Systems (complete or partial) or equipment under initial test where

high energy will be introduced for the first time must be physically
walked down to ensure unauthorized personnel are removed from
test areas. As required, personnel may be stationed at designated
locations to keep test areas free of unauthorized personnel.
Emergency egress routes must be identified and verified clear of
obstructions.

5.2.3 Equipment Lockout/Tagout (LOTO) requirements in support of this

activity must be implemented in accordance with 4TP-H09-00001,
System and Equipment Safety Tagging/Lockout.

5.2.4 Special attention must be provided for protection of personnel and

equipment. Ensure precautions such as barriers, flagging, danger
signs, horns, area restrictions, etc., are used to protect personnel
and equipment.

5.2.5 Immediately terminate testing if any unusual noises, smoke or

anomalies occur, or if design limits that may compromise the safety
of personnel or equipment are exceeded. Immediately notify the
Project Startup Manager and the site ES&H representative (if
applicable) of such occurrences.

5.2.6 Assure adequate access is provided to all required areas during the
test. Where permanent access is not provided, scaffolding or a
manlift must be provided in accordance with job site procedures.

5.2.7 Establish appropriate level of communication between test and

control room personnel.

5.2.8 Follow the requirements of 4MP-T81-03314 procedure (Working on

or Near Energized Circuits) as appropriate.

5.2.9 Loose fitting clothing or long hair shall be properly secured to

prevent entanglement when working around moving equipment.

5.2.10 Rotating parts, such as couplings, pulleys, external fans, and

unused shaft extensions, should have permanent guards installed to
prevent accidental contact with hands or clothing. This is particularly
important where the parts have surface irregularities such as keys,
keyways or setscrews.

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 MOTOR RUN TESTING No. 530-U07-00306
Rev. 0
Page 5 of 11

5.2.11 Loose parts of the coupling that cannot be removed for the motor
uncoupled run-in shall be tied off or affixed in such a way that they
shall not contact the motor shaft or any other rotating part.

5.2.12 Do not operate any equipment unless its supervisory and protective
devices are calibrated, tested, and functional. No protective devices
shall be de-rated or bypassed unless temporary protection is
provided.

6.0 PROCEDURE

6.1.1 Note: The vendor’s instruction manual takes precedence over this
procedure in the event of conflicts. Detailed equipment operation
shall be according to vendor manuals.

6.2 General

6.2.1 This test shall be performed concurrently with Equipment Vibration

Testing, and Driven Mechanical Equipment Testing. The Startup
Engineer will coordinate all activities as necessary.

6.2.2 Motor run-in time shall be as specified by the vendor or until bearing
temperatures and winding temperatures (as applicable) stabilize. A
temperature is normally considered stable when three successive
readings taken at 10-minute intervals do not vary by more than ±3
percent.

6.2.3 During initial run-in, record those equipment parameters that have
an accessible indicator. Typical parameters that establish the
motor's characteristics include bearing temperatures, winding
temperatures, cooling fluid temperatures, lubrication flows and
temperatures, etc. The data should have a common time basis and
be recorded at a specified interval. The following are several
acceptable recording methods:

• The plant DCS or computer

• A chart recorder

• A data logger

• Manual recording of local indicators

6.2.4 Use the Motor Data Record, Exhibit B, to document test results and
attach charts, graphs, data printouts, etc. Data collection can be
stopped when monitored parameters have stabilized.

6.2.5 Record the ambient temperature and the cooling water temperature
to judge if the bearing temperature is stabilized or not.
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 MOTOR RUN TESTING No. 530-U07-00306
Rev. 0
Page 6 of 11

Note: Ambient temperature and fluid temperature shall be recorded

6.2.6 Measure bearing vibration at three direction of each 90 º distance

(Vertical, Horizontal and Axial)

Note: Vibration shall be measured each 30 minutes and judged at

rated capacity, speed under stabilized load condition

6.2.7 During the coupled run-in of variable or multi-speed equipment data

should be taken at:

• Minimum (or low) speed,

• Anticipated normal speed, and

• Maximum (or high) speed.

Note: On variable speed equipment, particular attention should be

exercised to avoid operation at, or near, the equipment
critical speed.

6.2.8 Temporary alterations installed during testing shall be recorded on

Exhibit 1, Motor Data Record. Temporary alterations that are to
remain following completion of testing shall be logged according to
the requirements of 520-U07-00226, Control of Temporary
Modifications.

6.3 Inspection

6.3.1 Ensure that the motor is clean and dry. The motor nameplate shall
be legible. End bells, covers, filters, and accessories shall be firmly
attached.

6.3.2 Record motor nameplate data on the Motor Data Record, Exhibit B.

6.3.3 Ensure that the voltage, phasing and the frequency of the motor’s
power supply agree with those on the motor nameplate and the
appropriate drawings.

6.3.4 Ensure that motor terminations are properly made up. On dual
voltage motors ensure that the winding connections are correct for
the supplied voltage and agree with those on the motor name plate.

6.3.5 Ensure Verify that the motor is properly grounded in accordance with
the project grounding notes, symbols, and details.

6.3.6 Ensure that collector rings and brushes checked as follow, The
collector rings shall be clean and free of any mechanical damage.

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 MOTOR RUN TESTING No. 530-U07-00306
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The brushes shall make good contact with the slip rings and the
brushes shall slide smoothly in their holders.

6.3.7 Ensure that the motor protection circuits have been set. If
Engineering has not provided initial settings the following may be
used:
a) Instantaneous trip (magnetic overloads or quick blow fuses) is
set at 10 to 12 times the full load amps (FLA) rating of the motor
or at the locked rotor (LR) amperage if given on the name plate
b) Timed trip (thermal overloads or slow-blow fuses) is set at the
FLA times the service factor (SF) of the motor.
c) Ground fault protection is set 15% of FLA and time delay shall
less than upstream setting time.

6.3.8 Record the initial settings in the comment section of the Motor Data
Record, Exhibit B.

6.3.9 Ensure that all protective relays have been calibrated and func-
tionally tested.

6.3.10 Ensure conduit connections for control and power cables ensuring
that bushings are installed, conduit connections are tight and covers
are installed.

6.3.11 Ensure connection between RTD of motor winding (as applicable)

and protection relay is correctly. Verify the winding temperature is
displayed correctly through protection relay.

6.3.12 Ensure motor vibration sensors are tested including alarm and trip
levels (as applicable).

6.3.13 Ensure any terminals of CT's (as applicable) installed on the motor
terminal box are connected to protection relay or shorted.

6.3.14 Ensure that motor cable shield are connected in accordance with
contract specification (as applicable).

7.0 PRE-RUN TESTS

7.1.1 The insulation of the motor windings and power cable should be
meggered prior to the initial run if not recently meggered. Insulation
Resistance (Megger) Testing for test voltages and acceptance
criteria.

7.1.2 The winding resistance shall be measured phase to phase and

measure the applied voltage phase to phase.

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 MOTOR RUN TESTING No. 530-U07-00306
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Page 8 of 11

7.1.3 Place any support systems, such as lube oil or cooling water, in
operation.

7.1.4 Rotate the motor shaft manually (if possible) to ensure that the rotor
moves freely, without rubbing.

7.1.5 Phase rotation may be initially checked using a motor phase rotation
meter for any motor. However, an initial check by motor phase
rotation meter is mandatory for motors and driven equipment that
might be damaged by reverse rotation:
a) Tag out the motor supply breaker.
b) Connect the leads of the phase rotation meter to the motor
terminals at the motor terminal box or feeder (load) terminals for
the motor at the starter or switchgear.
c) Slowly rotate the motor shaft (rotor) in the proper direction of
rotation for the driven equipment and verify that the phase
sequence on the meter matches the phase sequence of the line
(supply) connections.
d) If the phase sequence indicated on the meter does not match
the design (line) phase sequence, interchange the motor leads
of two phases at the motor terminal box or at the starter or
switchgear.

NOTE: If leads need to be swapped all labels, tags, markings, etc.

need to be revised to match issued drawings.
a) Recheck the phase sequence of the motor winding using steps
b. and c. above and record the sequence on the Motor Data
Record, Exhibit B.
b) Remove the tagout.

7.1.6 For a motor supplied from a load center or switchgear bus, place the
breaker in the operating position (racked-in). For a motor equipped
with a starter and supplied from a motor control center and/or
distribution panel, place the breaker in the closed position. Ensure
that the motor space heaters, if supplied, are energized and note
their operation in the comment section of the Motor Data Record,
Exhibit B.

NOTE: Space heaters must be energized for the minimum amount

of time required by the manufacturer prior to attempting a motor
start. If no guidelines are given the heater should be energized for 8
hours prior to attempting the start.

7.1.7 After the preliminary rotation verification all motors must be

“bumped” for a final verification of proper rotation.

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 MOTOR RUN TESTING No. 530-U07-00306
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Page 9 of 11

7.2 Motor Start and Run

7.2.1 If, at any time during the implementation of this procedure, any
parameter or condition is out of acceptable limits and cannot be
readily corrected, the evolution in progress shall be terminated and
the system or component placed in a safe configuration.

7.2.2 Clamp an ammeter on one of the motor leads either at the motor
terminal box or at the breaker or use current indicator installed on
the circuit breaker cell (as applicable) and set it to record the
maximum current draws. Start the motor, locally if possible. Record
the starting current on the Motor Data Record, Exhibit B.

7.2.3 As the motor comes up to speed, monitor it for smoothness of

operation and for any unusual or unexpected noises.

7.2.4 With the motor running: take running current on all phases, phase to
phase voltages, motor rpm measurements and verify that the motor
space heater is de-energized. Record readings on the Motor Data
Record, Exhibit B.

7.2.5 If applicable tune variable speed drive to the system attributes and
verify frequency settings.

7.2.6 Check that the motor bearings are being properly lubricated (e.g.
bearing oil rings are rotating, no excessive foaming, levels are
correct). Monitor bearing temperatures as the motor is run in. When
they have stabilized, record the measurement.

7.2.7 Monitor motor winding temperatures, if available. When they have

stabilized, record the measurement on the Motor Data Record,
Exhibit B, in the comment section.

7.2.8 Take vibration data as required. Refer to procedure 530-U07-00302,

Equipment Vibration Testing. Vibration readings that exceed limits
may result in motor damage, and operation may have to be secured.

7.2.9 Verify temperature, current, and vibration readings against any local
or remote indications.

7.2.10 Verify magnetic center position indication. Apply new mark if

necessary.

7.2.11 When the vendor’s run-in criteria have been met or the temperatures
are stable secure the motor and monitor for smooth coast down.

7.2.12 Repeat the activities of the uncoupled motor start and run-in when
the motor is coupled. Record the data on the Motor Data Record,
Exhibit B.
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 MOTOR RUN TESTING No. 530-U07-00306
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Page 10 of 11

7.2.13 After final alignment and motor and driven equipment run-in, the
motor may be doweled in position as required by the vendor.

7.2.14 Check motor noise level to be within contract specification limits.

7.3 Restoration

7.3.1 Verify that temporary alterations made during the performance of

this test have been restored or controlled according to 520-U07-
00226, Control of Temporary Modifications.

7.3.2 Verify that temporary test equipment has been removed, and all
system connections and permanent equipment are replaced and
secured. Ensure terminal box cover is tight and has appropriate
gasket installed.

7.3.3 Verify that equipment and system(s) affected by this procedure are
restored to conditions as specified by the person responsible for the
system(s).

7.3.4 Notify the Operations Supervisor, using Project process, that testing
is complete.

8.0 ACCEPTANCE CRITERIA

8.1 All equipment operating parameters including currents, voltages,

resistances, Vibration and temperatures shall be within project
design and vendor requirements and tolerances. The motor
operation shall be generally smooth.

8.2 Insulation Resistance

Refer to the vendor’s manual or procedure 530-U07-00308,

Insulation Resistance (Megger) Testing for acceptable insulation
resistance. In some cases the motor may be run for an extended
period of time to dry out the motor and allow the insulation
resistance to increase over time.

9.0 REFERENCES
• Electrical Single-Line Diagrams
• Electrical Schematic Diagrams
• Grounding Notes, Symbols, and Details
• Vendor’s Instruction Manual and Associated Drawings
• Equipment Vibration Testing, 530-U07-00302
• Driven Mechanical Equipment Testing, 530-U07-00303
• Insulation Resistance (Megger) Testing, 530-U07-00308
• Control of Temporary Modifications, 520-U07-00226

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 MOTOR RUN TESTING No. 530-U07-00306
Rev. 0
Page 11 of 11

• 4TP-H09-00001, System and Equipment Safety

Tagging/Lockout
• 4MP-T81-03314, working on near energized circuits.

10.0 EXHIBITS

10.1 Attachment A - Check list

10.2 Attachment B - Motor Data Record

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 No. 530-U07-00306
MOTOR RUN TESTING Rev. 0
PAGE 1of 1

EXHIBIT A
CHECK LIST
Sheet _1_ OF _1_

Check list :
Item DESCRIPTION STATUS NOTE
1 Ensure the motor under test is installed correctly without punch list item
category A
2 Verify that test equipment used for recording data are calibrated within
their calibration interval
3 Verify that the motor bearing lubrication and cooling system, if any, is available
for operation.
4 Verify that instrumentation, controls, and alarms associated with the equipment
under test are tested.
5 Verify that the motor supply breaker/switchgear has been functionally tested
6 Verify vendor’s precautions and limits, such as number of starts, run-in duration,
vibration, load,…etc.
7 Verify equipment Lockout/Tagout (LOTO) requirements in support of this
activity have been implemented.
8 Temporary alterations installed during testing shall be recorded.
9 Ensure that the voltage, phasing ,the frequency and motor terminations are
correct for the supplied voltage and agree with those on the motor name plate and
10 Ensure that MV motor power cable shield is grounded only from one side
(motor side) as per mentioned in the termination cards.
11 Verify that the motor is properly grounded in accordance with the project grounding
notes, symbols, and detail.
12 Verify the collector rings (as applicable) is cleaned and free of any mechanical damage.
The brushes shall make good contact with the slip rings and the brushes shall slide
smoothly in their holders.
13 Ensure that the motor protection circuits have been set.
14 Ensure connection between RTD of motor winding (as applicable) and protection relay
is correctly.
15 Ensure motor vibration sensors are tested including alarm and trip level (as applicable)
16 Ensure any terminals of CT's (as applicable) installed on the motor terminal box are
connected to protection relay or shorted
17 Ensure that the motor space heaters, if supplied, are energized
18 Check motor rotation .
19 Verify the shaft is turning smoothly.
20 There is no abnormal noise or smell.
21 Verify that temporary alterations made during the performance are restored.
22 Verify that temporary test equipment has been removed.

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 No. 530-U07-00306
MOTOR RUN TEST REPORT Rev. 0
PAGE 1of2

EXHIBIT B
MOTOR DATA RECORD
SHEET
_1_ OF _2__

SDN No.______-___-___-____-_____-___

EQUIPMENT IDENTIFICATION
FACILITY/PROJECT UNIT NO. JOB NO.

SYSTEM NAME/NUMBER EQUIPMENT NAME/NUMBER

POWER SOURCE DRAWINGS

PREREQUISTIES COMPLETE AND SAFETY PRECAUTIONS READ AND COMPLIED WITH: STARTUP ENGINEER DATE
__________________________/________

MOTOR NAMEPLATE DATA

MFG ID# SERV #
VOLTS AMPS AMPS (LR) RPM
FRAME HZ HP/KW ENCL
CODE DUTY AMB SF

TYPE INSUL. NEMA NEMA EFF.

CLASS DESIGN.
# BRG'S IB/DE OB/NDE

MOTOR OPERATING DATA

MEGGER READINGS A-G MOHMS N-G MOHMS
WINDING RESISTANCE A-B OHMS B-C OHMS C-A OHMS
APPLIED
A-B VOLTS B-C VOLTS C-A VOLTS P-N VOLTS
VOLTAGES
PHASE SEQUENCE BUS VOLTAGE VOLTS
STARTING CURRENT (AMPS) RPM RUNNING CURRENT (AMPS)
MODE
UNCOUPLED COUPLED UNCOUPLED ∅A ∅B ∅C
PHASE
COUPLED,
A B C ∅A ∅B ∅C
LOW
COUPLED,
ROTATION: CW CCW ∅A ∅B ∅C
MEDIUM
COUPLED,
∅A ∅B ∅C
HIGH

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MOTOR RUN TESTING Rev. 0
PAGE 2of 2

EXHIBIT B

MOTOR DATA RECORD (CONT’D.)

SHEET
_2_ OF 2___

MOTOR OPERATING DATA (CONT’D)

Time (0) (0:10) (0:20) (0:30) (0:40) (0:50) (1:00) (1:10) (1:20) (1:30)
Param. : : : : : : : : : :
Ambient
Temperature
DE Brg.
Temp.
NDE Brg.
Temp.
Current
L1,L2,L3
Voltage L1-2,
L2-L3,L1-L3
Vibration Bearing 1 Bearing 2
Time.
V H A V H A

MEASURING AND TEST EQUIPMENT

TEST INSTRUMENT MANUF./MODEL M&TE/TAG NUMBER CAL. DUE DATE

TEST MODIFICATIONS
INSTALLED RESTORED
MODIFICATION STARTUP ENGINEER / DATE STARTUP ENGINEER / DATE

COMMENTS

STARTUP ENGINEER (PRINT/SIGN) DATE

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