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 & 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 |