Chapter no: 03

Testing and maintenance of rotating machines Marks:20

State the objective of testing (routine, type and special test) . Explain the role of BIS
(Bureau of Indian Standards) in testing of electrical machines & example of each test.
Following are the objectives of testing:-
1. Objective of testing is to finding error/defects in machine/equipment/ product.
2. To confirm whether the results obtain during testing are within tolerance limits specified by
BIS / ISS.
3. To provide an indication of the product reliability and quality.
4. To determine the quality of material used & workmanship.
5. To avoid inconvinces, accidents, minimize risk & for safety purpose.
6. To confirm whether machine/equipment/ product is manufactured as per design data or not.
7. To confirm whether the performance of machine/equipment/ product is as per design data or
not.
8. To determine that the machine/equipment/ product appears to be working as stated in the
specifications
9. Testing of equipment/machinery is also done after major maintenance of machine/equipment
10. Testing in all respect is also required when a new design or modified design is used,
11. To check whether the new product works as per the revised designed or not.

Role of BIS in testing of electrical machines:-

Roles of Bureau of Indian Standards (BIS) in testing of electrical equipment’s are as below:-
1. To specifies the standards for particular in machine/equipment/ product /materials etc.
2. To gives limit of losses& efficiency for particular in machine/equipment/ product.
3. To provide an indication about the product reliability and quality.
4. To issue licenses or Certification (ISI Mark) to manufacturers whose products are as
per BIS/ISS specified standards.
5. To avoid inconveniences’ & accidents BIS plays important role.

Example of each Test:-

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i) Routine Test :-
It is Conducted on each and every Product/Part for example as below
1. Insulation resistance Test.
2. Winding resistance Test.
ii) Type Test: -
These tests are carried out on 2 or 3 randomly machines from the lot of the manufactured
machines of same design and specification. For example as below
1. Temperature-rise type test.
2. Dielectric type tests.
iii) Special Test :-
These are performed for specific purpose only as per demand of customer for example as below
1. Measurement of acoustic noise level.
2. Vibration Test

External causes of failure of equipments.

External causes for the Failure of electrical equipments:-

1. Overvoltage/ under voltage
2. Unbalanced voltage
3. Over frequency / under frequency
4. Single phasing from supply side
5. Lightning surge

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6. Overloading for long time
7. Unbalanced loading
8. High ambient temperature
9. Loose connection
10. Short circuit fault in supply system

Effect of misalignment in rotating machine:

Effect of misalignment on the performance of machine:-

1. There will be excessive vibrations.
2. Increase noise level.
3. The shaft will bent.
4. Increases in friction loss.
5. Premature bearing and coupling failure
6. Premature failure of belt/Rpope/chain in case of indirect drive.
7. It increases maintenance cost.
8. It increases energy consumption.
9. It reduces motor efficiency.
10. Overall performance of machine reduces.
11. Early wear & tear of both driving & driven machine.
12. Loose or broken foundation bolts and coupling bolts
13. High bearings temperature.
14. High lubricating oil temperature.

What is indirect method of testing ? What are its advantages and drawbacks ?
Indirect loading Method
In case of indirect testing method equipment/machine are not directly loaded but instead of
loading machine runs on No- load. To determine the performance of machine.
Advantages indirect method of testing:
1. Power consumption is less.
2. Time required is less.
Disadvantages indirect method of testing:

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1. Result obtained is approximately equal.

Compare Direct and Indirect methods of testing:

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Troubles in case of D.C machines.

Explain with circuit diagram of open circuit voltage ration test on 3 phase slip ring I.M.

Circuit Diagram:

Explanation:

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Routine test conducted on Synchronous generator:

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Direct loading test on 3-Ph induction motor? Draw necessary circuit diagram.

a) Full Load Test Circuit Diagram: ( If generator is coupled with induction motor):

OR

Explanation:-
 Increase the applied voltage to the stator gradually up to its rated value.
 Now increase load gradually and measured the readings of applied voltage, current, Power,
and Speed for various loads on the motor up to full load.
Observation Table:-

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 OR
b) Full Load Test Circuit Diagram (If Brake arrangement is used):-

Explanation:
 Connect the circuit as shown in circuit diagram.
 Switch ON supply and start the motor.
 Increase the load gradually on the motor up to full load.

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State the function of following tools : (i) Bearing puller (ii) Filler guage (iii) Dial tester (iv)
Spirit level (v) Earth tester (vi) Megger (vii) Growler

i) Bearing Puller:-
 Bearing puller is used for holding and removing the bearing safely
 It is also used to remove gears or pulleys from a shaft.
ii) Filler guage:-
A feeler gauge is a tool used
 To measure gap widths.
 To measure the clearance between two parts.(e.g. air gap between stator & rotor)
iii) Dial tester:-
 Is used to check the run-out (Unbalance) of rotating parts (commutators, rotor, shafts)
 Also used to check the mis-alignment of shaft in electrical machines.
iv) Spirit level:-
 It is used to check the level. OR
 To indicate whether a surface is horizontal (level) or vertical (plumb).

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v) Earth Tester :-
It is used to measure earth resistance.
vi) Megger :-
Megger is used to find out (measure) insulation resistance of electrical machine/equipment.
vii) Growler:-
A growler is an electrical device used to find out shorted turn faults in armature winding and
stator winding of motor.

State factors involved in designing the machine foundation.

Following information is required to start the foundation:-

1. Drawings of machine from foundation design point of view
2. Dimension of the machine:-
 Its length
 & width
 Height of machine
3. Information about condition of soil:-
 Bearing capacity of soil
 Soil density
 Ground water table location
4. Weight of machine:-
 Erection weight
 Operating weight
 Imposed weight
 Accessories weight
5. CG location in static and operating condition.
6. Level of plinth should be above the maximum flood level of the site.
7. Ground water level.
8. Whether machine is static, Rotating or Reciprocating.
9. Surrounding atmospheric condition.
10. Earth quake resistance should be considered while designing foundation.
11. The foundation should be able to absorb the vibration while operating at its full capacity.

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12. The dimension of foundation should be proportional to safe bearing capacity of soil.
13. Install the machine in a well-ventilated area.
14. There should be easy accessibility provided to all indicating and protecting devises.
15. There should be sufficient place all around the machine.
16. Precautions should be taken to prevent leakage of water into machine room.
17. Direct sunlight, rain, water, dust, gases, smoke should be not be present in the room.

Ojective and procedure of performing reduced voltage running up test on 3-ph I.M.

Objectives:-
1. The test is applied to squirrel cage motors
2. To determine the ability of motor to run equal and nearly equal to rated speed of the motor
even at reduced voltage.
3. To see whether there is any tendency of crawling presents in the motor at reduced voltage.
4. This test is also conducted to check the noisy running of motor
5. To check whether , noise level, speed is within the tolerance limit or not
Circuit Diagram:

Procedure:-
1. Run the motor with rated voltage & measure the speed.
2. Now apply the reduced voltage 1/ 3 of rated value and measure the speed
a) The motor below 37 KW, conduct the test in both direction.
b) For motors above 37 KW, conduct the test only in specified direction of rotation.
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Troubleshooting chart for 3phase squirrel cage induction motor.

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Possible causes for each of the following trouble of a 3 phase slip ring induction motor. (i)
Motor runs hot (ii) Motor runs slow (iii) Motor fails to start (iv) Excessive sparking
between brushes and slip rings.
Sr.No Type of fault/abnormal Causes
conditions/Troubles
1 Motor Runs Hot  Single phasing.
 Overload
 Over/Under voltage.
 Unbalance voltage
 Over/Under frequency
 Poor motor ventilation/ Air flow obstructed or inadequate
ventilation.
 Ventilating Fan is not working
 Rotor rubbing on stator
 Worn bearings
 High ambient temperature at the motor controller. (above
400C)
 Excessive core loss.
 Stator winding is in correct connected (Wrong connection)
 It may be due to internal faults inside the winding or for
winding to earth.
 Check the correct starting time and duty cycle.
 Broken rotor bars
 Shorted stator coils
 Dirt in motor
2 Motor Run Slow  Low voltage.
 Low frequency.
 Single phasing.
 Overload
 Stator connected in star instead of delta.
 Improper connection of motor leads to supply line

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  Shorted stator coils
 Broken rotor bars
3 Motor Fails to Start  Terminal voltage too low
 Blowing of fuse/single phasing.
 Defective starting mechanism
 protection devices has been tripped
 The motor controller will not operate
 Short circuit in supply cable.
 Open circuit in supply cable.
 Loose contact.
 Motor rotor, bearings or driven load is locked.
 Overloaded
 Bearing is seized (Frozon).
 Check the rotor resistance circuit and control.
4 Excessive Sparking  Line current is more
between brushes & slip  Brushes are bedding or sticking in holders-not properly
ring in slipring  Dirt is accumulated on brushes
I.M.  Improper pressure and spring tension.

Requirements of foundation of rotating machines.

1. The foundation should be strong/ rigid .
2. The foundation should be able to absorb the vibration while operating at its full capacity.
3. The foundation should be able to withstand against erecting weight, accessories weight,
operating weight etc.
4. For concrete foundations use concrete ratio of 1:2:4.
5. The foundation should be well cure before machine put on it.
6. The dimension of foundation should be more than actual requirement.
7. Depth of foundation should be proportional to the bearing capacity of soil.
8. The surface of foundation must be protected from machine oil by means of suitable chemical
coating or suitable chemical treatment.
9. Level of foundation should be above the maximum flood level of the site.

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10. There should be easy accesses towards machine foundation
11. The foundation should be sufficiently rigid to maintain proper alignment between the motor
and the driven machine.

Equivalent circuit if induction motor referred to stator:

OR

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 OR

Draw the vector diagram of three phase induction motor and justify that three phase
induction motor is a generalised transformer.

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Justification induction motor is a generalised transformer.-
An induction motor is similar to a transformer in many respects. In view of these similarities, an
induction motor is called as a generalized transformer & it is for this reason that the stator
winding of an induction motor is treated as its primary and the rotor winding as its secondary.
The only difference is the secondary of induction motor is rotating and short circuited while
transformer secondary is stationary and connected to load. The load on induction motor is
mechanical while load on transformer is electrical.

Procedure of conducting (i) High voltage test (ii) Quiet running test on a single phase I.M:

(i) High voltage test:-

A high voltage is applied between windings and frame of the motor. The high voltage test should
be applied once and once only to a new and completed motor in normal working condition.
The high voltage test should not be applied when the insulation resistance is less than the
required value.

The high voltages are as under: For duration of 60 sec.

S.No. Rated Voltage of Motor Test Voltage
1 50 Volts or less 500 Volt
2 Above 50V up to and including 250V 1000 Volt

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(ii) Quiet running test:-
When running with the load the motor creates noise, which should be below the specified noise
level.

Procedure of levelling and aligning of direct coupled drives. Also draw the figure showing
the position of packing materials:

Procedure:-
 Align the motor and the driven machine on bed-plate.
 Firstly aligned center axis of both the shafts in the same line
 Aligned both the shafts correctly in the horizontal plane.
 Aligned both the shafts correctly in the vertical plane.
 Aligned both the shafts correctly on the same center axis.
 Any variation in levels is corrected by adding or removing shims
 To check alignment there are three methods:-
1. By visual inspection, combined with straightedge or ruler:- This method has less accuracy.
2. By use of Dial Indicator: - This method has high accuracy.
3. By use of Laser- guided tools: - This method has highest accuracy.

Figure showing the position of packing materials:

OR

Objective & Procedure of conducting H V test on a three phase I.M as per IS 4029-2010.

Objective:-
 To determine the weakness of insulation, damaged insulation or insufficient clearances etc.

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 To determine the level of insulation of the motor.
OR
 To identify the condition insulation used,
 To identify the quality of insulation used.
 To identify the withstand capacity of the insulation at high voltage for short duration.
 To check the insulation property between-
1. Stator and earth.
2 Rotor and earth
3 Stator and rotor

Procedure:-
 The test voltages should be of power frequency and as far as possible should have a sine wave
shape.
 This test consists in applying the specified test voltage between the various windings and
earth.
No Description Test Voltage (for 60 sec.)
.
1 Stator Windings 1000V + Twice rated voltage with a minimum of
1500 Volts
2 Rotor windings of slip ring 1000V + Twice open circuit standstill voltage as
induction motors (unidirectional) measured between slip rings with (unidirectional)
rated voltage applied to stator windings
3 For motors to be reversed or braked 1000 V+ Four times open circuit standstill voltage
while running , rotor winding

Conclusion :-
 During high voltage test if no failure of insulation occurs at full test voltage then test is
successful. i.e. quality & level of insulation is good.

Draw and explain the circuit diagram to perform no load and S.C. tests on 3-Ph I.M:

Diagram:-
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Explanation of No Load test:-
i) The stator windings are connected through auto transformer to a supply of rated frequency.
ii) Increase the voltage gradually up to its rated voltage given on the rating plate.
iii) Machine will run close to the synchronous speed due to no-load.
iv) Take the corresponding readings of input voltage (VO), input current (I0) and input power
(W0)
S.C. test :-
During this test rotor is blocked
Explanation:-
i) Hold the rotor stationary with the help of jaw/clamps/ hand for small motors. (That is short
circuit test)
ii) Keep the auto transformer at zero volt position initially.
iii) Increase the applied voltage to the stator gradually with the help of auto transformer in steps
till it circulates full load current.
iv) Take the corresponding readings of input current (full load current) (ISC), input voltage
(VSC), and input power (WSC).

What are the permissible limits for safe working of electrical machines ?

1. Voltage: The terminal voltage is  10% of rated voltage. For a period of 10 sec. (T.V.
differing from rated value by not more than 6 %.)
2. Unbalanced voltage: The permissible unbalance in supply voltage should not exceed 1%. For
a period of 15 sec
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3. Frequency: Supply of frequency is  5% of rated frequency. For a period of 10 sec.
(Frequency differing from its rated value by not more than 3 %.)
4. Voltage and frequency: Any combination of a) & b)  10% For a period of 10 sec
5. Unbalanced Current :- The permissible unbalance 8% For a period of 15 sec
6. Starting Current: Less than 4.5 times the rated current.
7. Over load (Momentary excess torque): Capable of withstanding for 15 sec. without stalling
OR abrupt change in speed 1.6 times their rated torque.
8. Slip: 20% of the slip for machine output 1 KW or more. For machines having output less
than 1KW 30% of the slip.
9. Over Speed:- Squirrel cage general purpose I.M. shall be designed to withstand 1.2 times the
maximum rated speed.& Crane duty I.M. shall be designed to withstand 2.5 times the
maximum rated speed. The duration of any over speed test shall be 2 Minutes
10. Variation of speed: - On highest side: 3% of synchronous speed. On lowest speed: + 3% of
synchronous speed.
11. Temperature rise: Shall not exceed by more than 100C for motors of output up to and
including 1000 KW and 50C for motors of output exceeding 1000KW
OR

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Define Tolerance. Give value of tolerance for power transformer as per IS 2026-2011

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