D R I V E S &
S W I T C H G E A R
D esigned to detect, locate and analyze insulating systems faults and winding
dissymmetry, Surge Comparison Test Machines (SCTM) offer the best diagnostic
capability as a single test in detecting the type of fault and often the cause of defect.
Inspection (testing) stators of AC
induction machines - Part 2
In Part 1 (VECTOR, October 2005 issue)
some tests were presented, including
insulation resistance (Megger and
PI) test, tan delta test, resistance and
impedance tests. Some characteristic
profiles with comments were given
relating to situations when a correct
dispersion of test results is required.
These should help repairers to detect
hidden defects, thus improving their
performance by extending electric motor
life expectancy.
Surge Comparison Test
Machines (SCTM)
These are non-destructive tests. The
manufacturer/repairer/operator need
to train themselves in the process,
as no specific literature is generally
available.
Choosing a SCTM
Sometimes the full output of an SCTM
Fig. 1: Estimated interval of
insulation breakdown.
by C.D. Pitis, Femco Mining Motors
may not reach the rated or required
output voltage. This occurs on low
impedance motors or on motors that
are too large for the SCTM capability.
One of the SCTM working conditions
is related to motor rated voltage.
For example, for a motor with
Unom = 3,3 kV 50 Hz, the SCTM has to
deliver a minimum test voltage of:
Utest = [2 x 3300 + 1000] x 2
= 11 000 V12 000 V
Minimum test inductance is another
criterion. For large formed coils
with low inductance (outside the
stator), the resonant frequency in
the surge test circuit ranges between
0,11,5 MHz. This requires high
f r e q u e n c y- r e s p o n s e m e a s u r i n g
equipment and flexibility, and is one of
the most difficult applications of surge
comparison testing. Special boosters
are required to test inductances of
L = 0,4 H.
The maximum pulse energy (MPE) is also
related to motor size. For example a
5 MW 11 V motor needs a SCTM with
MPE = 11 while a 150 kW 525 V motor
needs MPE = 0,3.
Links between the SCTM and a PC
enable a superior test approach with the
ability to do customised tests, and store
profiles, statistics, history, trends, etc.
DC step voltage test
Most electrical associations recommend
this procedure. The test should be
performed after a PI test has been
November 2005 - Vector - Page 25
performed. The SCTM is capable of
gradually increasing the voltage to the
desired test level:
Utest = [2 x Unom + 1000] x k
where k = 1 for old windings, or k = 2
for new windings before impregnation,
or k = 1,7 after impregnation.
By increasing the test voltage in steps
(increments), the leakage current can
be monitored to observe any sharp
increase, and to avoid a possible
insulation breakdown (Fig. 1).
Estimated interval of insulation
breakdown
Fig. 1. Shows the incipient insulation
breakdown graph test for an 830 kW,
6,6 kV motor at 12 C in January 2002.
Up to a test voltage of 6,0 kV DC
(point B), the insulation resistance has
a constant slope equal to 90 M.
Above 6 kV, a change in slope can be
noticed, with the insulation resistance
becoming 60 M at 9 kV (point C).
Above this value, insulation breakdown
is expected if a Hipot test is performed
(Point D) estimated 40 M. Corrected
values of insulation resistance at 40 C
temperature are:
- Point B: 10,0 M
- Point C: 6,7 M
- Point D: 4,5 M
The minimum recommended value of
insulation resistance is:

Fig. 2: Monitoring trends of DC
step voltage tests.
Rmin =[1 + 6600/1000]
= 7,6 M at 6,6 kV
The motor came in for repair as a
result of the insulation test trend results
monitored since 1992, as plotted in
Fig. 2.
Converted values of insulation
resistance at 40 C over the
years had the following trend:
May 1992: 130 M,
June 1997: 37 M,
Feb. 1998: 33 M,
Feb. 2001: 10 M.
In 2001, the full test voltage was not
applied due to high leakage current
i.e. 980 A. Weak insulation will show
declining M values as the voltage is
increased.
Before stripping, the stator was re-tested
in the workshop. The insulation recovered
slightly, possibly due to internal dipole
re-orientation by relaxation.
The DC step voltage test is not performed
to break-down the insulation, but to
ensure that the insulation does not break
Fig. 4: Transformer effect of the
hot spots on laminations.
Fig. 3:
down at a prescribed test value. The
test voltage is less than rated dielectric
strength. If the insulation fails under test,
it becomes known that the insulation to
ground was unreliable.
Surge (impulse) test
Switching of loads and lightning strikes
are known to cause high voltage
surges. The first few turns of the stator
of an electric motor can experience
voltage surges up to 10 times the actual
operating voltage of the motor. Studies
have shown that a very rapid surge may
be distributed across the first 10% of the
stator winding.
The surge test applies a high voltage
impulse into a coil, groups or phase(s).
The SCTM capacitors and the winding
circuit form a complex R-L-C circuit,
giving a damped oscillation with a
frequency much higher than the mains
frequency (50 Hz). As the impulse
propagates, it locates the insulation
weakness. Whilst raising the output
voltage, the waveform peaks of the
traces must be observed. They will begin
to flutter or fluctuate just prior to any
breakdown of insulation. Such failure
on a diamond coil is presented in Fig.3
(red arrow) compared to a healthy
coil (blue arrow), where peak flutters are
present prior to dielectric break down.
The maximum voltage based on the worst-
case distribution of a surge in the winding
is 1,5 x the winding operating voltage.
November 2005 - Vector - Page 26
Electromagnetic distortions on
fitted coils surge test.
Some insulation faults can be related to
the wave pattern measured during the
above surge (impulse) test.
A short-circuit between turns involves
reduced values of R and C i.e.
the time constant will be reduced,
giving only slight damping of the
output wave, but the output V will be
reduced because of a higher value
of absorbed current (shifting peak);
Faulty insulation to earth, or
inadequate adhesion of insulation
film to copper, will increase the value
of leakage current, thus reducing the
output V, while the damping will be
insignificant.
Small damping and wave shifts for
one or a group of coils whilst the
coils are in very good condition can
be related to damaged lamination
insulation or iron core hot spots
(Fig. 4).
Surge comparison test (SCT)
The SCT is the only means devised to
stress, test and analyse the integrity of
the interturn, intercoil or interphase
insulation, and subject them to higher
stresses than ground insulation. In a
SCT, two identical high voltage and high
frequency pulses are simultaneously
imposed on two phases, as two
separate R-L-C circuits, and the induced
reflections of both pulses are displayed,
superimposed upon each other. A faulty
circuit will give a different trace wave
pattern. A useful chart presents a typical
winding fault in Fig. 5.
On large machines due to the possible
existence of physical non-symmetry
on the input, unbalanced inductances
and/or capacitances could be present.
These could produce wave distortion
and/or separation.
Waveform analysis
SCT waveforms provide signatures,
patterns or traces that serve:
To determine the precise output
voltage during SCT;
To observe any differences in the
impedances of the two windings
during SCT.
The differences in recorded waveforms
may be:
Static or permanent separation, in
proportion with the test voltage;
Dynamic separation, starting from a
specific voltage level, and showing
wave instability or flickering.

Fig. 5: Wave shapes of typical winding faults.
November 2005 - Vector - Page 28
Three types of separations are typically noted (Fig. 5):
Only at the beginning of the wave form;
Difference in the peaks (change in amplitude);
Change in amplitude and frequency (phase shift).
Separation at the beginning of a waveform and changes in amplitude can
be related to tester ability.
Phase shift indicates short-circuits. If the wave pattern changes and
becomes erratic, then intermittent shorting or arcing is occurring in one
of the windings under test.
Steady separation of the traces indicates solid shorts, or incorrect turns
count, or wrong connection.
Large stators with parallel windings may show little or no separation for
shorted or open windings, the inductance change caused by these faults
being undetectable. As a result, it is critical to perform a SCT on each of
the parallel windings individually.
Conclusions
A insulating system is an assembly of insulating materials associated with
conductors and supporting the structural parts of the stator winding of a
motor.
Experience gained by testing a large variety of stators will always allow
a better evaluation and failure prediction. The author found that a
stethoscope is a very useful tool in identifying the exact point of discharging
on SCT.
Further tests will be presented in Part 3 of the article, in a subsequent issue
of VECTOR.
Contact Dan Pitis, Femco Mining Motors,
Tel (012) 250-2101, danpit@femco.co.za