INSULATION RESISTANCE TEST

INSULATION RESISTANCE TEST EQUIPMENT RATED LINE TO LINE VOLTAGE
U = < 1KV 1 - 2.5 KV 3 - 5 KV 6 - 12 KV > 12
All the coils / bars / completed winding before and after HV test (IEEE 95 - 1977) 500 V 500 - 1000V 1000 - 2500V 2500 - 5000V 5000 - 10,000V

POLARISATION INDEX TEST (PI)

POLARISATION INDEX TEST (PI) EQUIPMENT RATED LINE TO LINE VOLTAGE
U = < 1KV 1 - 2.5 KV 3 - 5 KV 6 - 12 KV > 12
All the coils / bars / completed winding ( IEEE Stds. 43 Sec. 5.4, 9.2 & 12.2 ) 500V 500 - 1000V 1000 - 2500V 2500 - 5000V 5000 - 10,000V

INTER LAMINAR INSULATION TEST

 
INTER LAMINAR INSULATION TEST Detected by Flux Loop or Core Tester (ELCID)
All the core pack of AC induction motor, Generators & DC Armature (IEEE Stds. 435 Sec. 9.1)

SUB CONDUCTOR TEST

SUB CONDUCTOR TEST  
All formed multi conductor stator coils / bars are tested before pre stack (CORAL Practice) Conductor to Conductor 1000 Volts. AC
All formed multi conductor stator coils / bars are tested after pre stack (CORAL Practice) Conductor to Conductor 500 Volts. AC
All formed multi conductor stator coils / bars are tested after moulding (ESI 44-7 - 1978) Conductor to Conductor 110 Volts. AC
 

HV TEST

Routine Test Standards Followed Machine System Voltage ( U ) and Test Voltage in KV
HV TEST 3.3 6.6 11 13.2
AC HV test on newly formed coils / bars in our works
at 1.3 (2 U + 1) (IEC 60034/BS 4999 & 5000)
10 18 30 36
AC HV test after positioning and wedging the coils / bars in the slots at (2 U + 3) (CORAL Practice) 10 16 25 29
AC HV test on completed stator winding after group forming before making internal star or delta (or) D (2U + 2) (CORAL Practice) 9 15 24 28
AC High Voltage test in front of the customer (2U + 1) 7.6 14.2 23 27.5

SURGE COMPARISION TEST

SURGE COMPARISION TEST  
After spreading the individual coil (1.5 U + 1) (CORAL Practice) 6 11 17.5 NA
After pre stacking the individual coils (1.5 U ) (CORAL Practice) 5 10 16.5 NA
After completing full moulding individual coils (1.5 U) ) (CORAL Practice) 5 10 16.5 NA
Complete stator winding (2U + 1) (EASA AR 100-2001) 8 15 23 NA
 

VOLTAGE ENDURANCE TEST

VOLTAGE ENDURANCE TEST (Schedule-A) (Schedule-B)
IEEE 1553 400 HOURS 250 HOURS
4.0 6.6 11 13.8 17 4.0 6.6 11 13.8 17
VOLTAGE ENDURANCE TEST VOLTAGES (KV)
8.7 14.3 23.9 30 36.9 10.1 16.7 27.9 35 43.1

THERMAL CYCLING TEST

THERMAL CYCLING TEST  
IEEE 1310  Measuring PD initially before start of thermal cycling, after completion of 50 cycles, after completion of 100, after completion of 250, after completion of 500.

TAN DELTA TEST

 
TAN DELTA TEST  
All the stator coils / completed stator winding (IEEE Stds. 432, Sec.8.1)  At 0.2 U, 0.4 U, 0.6 U, 0.8 U &amp; 1.0 U

DIMENSIONAL CHECKING

DIMENSIONAL CHECKING  
After completing entire moulding (ESI 44-7 - 1978)  All the coils / bars
 

RESIDUAL LIFE ASSESSMENT TEST (RLA)

Test Part Standards Follow
Winding Resistance Test Stator, Rotor and Exciter Parts BS 4999 Part 60 : 1976
Insulation Resistance Test Stator, Rotor and Exciter Parts IEEE 95 - 1977
Polarisation Induction Test (PI) Stator, Rotor and Exciter Parts IEEE Stds. 43 Sec. 5.4, 9.2 & 12.2
Hi-Pot Test
(Dielectric Absorption Test)
Stator, Rotor and Exciter Parts IEC 34 - 18 - 33
IEEE Stds. 432 - 1992
Inter Lamination Test High Voltage AC Stator winding IEEE Stds. 435 Sec. 9.1
Tan Delta Test High Voltage AC Stator winding IEEE Stds. 432, Sec.8.1
Inter Turn Insulation Test
(Surge Comparison)
Stator, Rotor and Exciter Parts EASA AR 100-2001
Recurrent Surge Oscillosgraph
(RSO) Test
Cylindrical Rotor IEEE Stds. 432 - 1992
Rotor Winding Impedance Test Cylindrical / Salient Pole / Cruciform Rotors IEEE Stds. 432 - 1992
Wedge Tightness Test Stator and Rotor IEEE Stds. 432 - 1992
Slot Discharge and Corona Probe Test High Voltage Stator IEEE Stds. 432 - 1992
Step Voltage Test High Voltage Stator IEEE 95 - 1977
Visual Inspection All Electrical & Mechanical Parts IEEE Stds. 432 - 1992

INSULATION RESISTANCE TEST EQUIPMENT RATED LINE TO LINE VOLTAGE
U = < 1KV 1 - 2.5 KV 3 - 5 KV 6 - 12 KV > 12
All the coils / bars / completed winding before and after HV test (IEEE 95 - 1977) 500 V 500 - 1000V 1000 - 2500V 2500 - 5000V 5000 - 10,000V
POLARISATION INDEX TEST (PI) EQUIPMENT RATED LINE TO LINE VOLTAGE
U = < 1KV 1 - 2.5 KV 3 - 5 KV 6 - 12 KV > 12
All the coils / bars / completed winding ( IEEE Stds. 43 Sec. 5.4, 9.2 & 12.2 ) 500V 500 - 1000V 1000 - 2500V 2500 - 5000V 5000 - 10,000V
INTER LAMINAR INSULATION TEST Detected by Flux Loop or Core Tester (ELCID)
All the core pack of AC induction motor, Generators & DC Armature (IEEE Stds. 435 Sec. 9.1)
SUB CONDUCTOR TEST  
All formed multi conductor stator coils / bars are tested before pre stack (CORAL Practice) Conductor to Conductor 1000 Volts. AC
All formed multi conductor stator coils / bars are tested after pre stack (CORAL Practice) Conductor to Conductor 500 Volts. AC
All formed multi conductor stator coils / bars are tested after moulding (ESI 44-7 - 1978) Conductor to Conductor 110 Volts. AC

 

Routine Test Standards Followed Machine System Voltage ( U ) and Test Voltage in KV
HV TEST 3.3 6.6 11 13.2
AC HV test on newly formed coils / bars in our works
at 1.3 (2 U + 1) (IEC 60034/BS 4999 & 5000)
10 18 30 36
AC HV test after positioning and wedging the coils / bars in the slots at (2 U + 3) (CORAL Practice) 10 16 25 29
AC HV test on completed stator winding after group forming before making internal star or delta (or) D (2U + 2) (CORAL Practice) 9 15 24 28
AC High Voltage test in front of the customer (2U + 1) 7.6 14.2 23 27.5
SURGE COMPARISION TEST  
After spreading the individual coil (1.5 U + 1) (CORAL Practice) 6 11 17.5 NA
After pre stacking the individual coils (1.5 U ) (CORAL Practice) 5 10 16.5 NA
After completing full moulding individual coils (1.5 U) ) (CORAL Practice) 5 10 16.5 NA
Complete stator winding (2U + 1) (EASA AR 100-2001) 8 15 23 NA

 

VOLTAGE ENDURANCE TEST (Schedule-A) (Schedule-B)
IEEE 1553 400 HOURS 250 HOURS
4.0 6.6 11 13.8 17 4.0 6.6 11 13.8 17
VOLTAGE ENDURANCE TEST VOLTAGES (KV)
8.7 14.3 23.9 30 36.9 10.1 16.7 27.9 35 43.1
THERMAL CYCLING TEST  
IEEE 1310  Measuring PD initially before start of thermal cycling, after completion of 50 cycles, after completion of 100, after completion of 250, after completion of 500.
TAN DELTA TEST  
All the stator coils / completed stator winding (IEEE Stds. 432, Sec.8.1)  At 0.2 U, 0.4 U, 0.6 U, 0.8 U &amp; 1.0 U
DIMENSIONAL CHECKING  
After completing entire moulding (ESI 44-7 - 1978)  All the coils / bars

 

Residual Life Assessment Test (RLA)

Test Part Standards Follow
Winding Resistance Test Stator, Rotor and Exciter Parts BS 4999 Part 60 : 1976
Insulation Resistance Test Stator, Rotor and Exciter Parts IEEE 95 - 1977
Polarisation Induction Test (PI) Stator, Rotor and Exciter Parts IEEE Stds. 43 Sec. 5.4, 9.2 & 12.2
Hi-Pot Test
(Dielectric Absorption Test)
Stator, Rotor and Exciter Parts IEC 34 - 18 - 33
IEEE Stds. 432 - 1992
Inter Lamination Test High Voltage AC Stator winding IEEE Stds. 435 Sec. 9.1
Tan Delta Test High Voltage AC Stator winding IEEE Stds. 432, Sec.8.1
Inter Turn Insulation Test
(Surge Comparison)
Stator, Rotor and Exciter Parts EASA AR 100-2001
Recurrent Surge Oscillosgraph
(RSO) Test
Cylindrical Rotor IEEE Stds. 432 - 1992
Rotor Winding Impedance Test Cylindrical / Salient Pole / Cruciform Rotors IEEE Stds. 432 - 1992
Wedge Tightness Test Stator and Rotor IEEE Stds. 432 - 1992
Slot Discharge and Corona Probe Test High Voltage Stator IEEE Stds. 432 - 1992
Step Voltage Test High Voltage Stator IEEE 95 - 1977
Visual Inspection All Electrical & Mechanical Parts IEEE Stds. 432 - 1992