Testing and

Maintenance of
Electrical Machines
(TME) 6430
 Unit 1 :
Basics of Testing
 Curriculum
Causes of failure of electrical equipments
Role of Bureau of Indian Standards (BIS) in testing
Significance of Maintenance of Electrical
Equipment
Types of Maintenance-Routine, Preventive and
breakdown Maintenance
concept of TPM, pillars of TPM
Factors affecting the preventive maintenance
schedule
Procedure for developing Preventive maintenance
schedule
Objectives of Testing
Categories of tests
Tolerances
Ingress protection for solids & Liquids, IP marking
Causes of failure of electrical equipments

External causes Internal causes

Causes of failure of electrical equipments

The external causes of failure

1. Sustained overloads
2. Single phasing
3. Unbalanced supply voltage
4. Over voltage or under voltage
5. Change in supply frequency
6. Short circuit fault in supply
system
 Causes of failure of electrical equipments
The internal causes of failure are mostly
because of the failure of insulation due to….

1. Temperature rise above permissible

limits for long time (overloading)
2. Short circuit in the windings or inter_turn
shorts
3. Phase to ground or Phase to phase fault
or single phasing
4. Open circuit
5. Magnetic locking (Cogging)
6. Uneven air gap (Unbalanced rotor)
 Causes of failure of electrical equipments

1. Rise in operating temperature

The major cause of failure of an electrical

equipment/machine in most of the cases is
the failure of insulation.

The insulation fails due to rise in operating

temperature of the machine / equipment.
The insulation used for machines is made
from organic compounds which contains
water.

At excessive temperatures it gets dried up

& oxidised, and it will became brittle &
gets disintegrated under vibrations.

No insulation last forever & deteriorates

slowly at low temperatures & more rapidly
at higher temperatures.
The higher operating temperature may be
due to …..
- Sustained over loads
- Improper cooling
- Blocked ventilating ducts due to
dirt, dust, lubricants

2. For rotating machines

unbalanced rotor may cause vibrations,
more frictional loss & damage of bearings
causing failure of machine.
3. The machines subjected to severe
atmospheric operating conditions such as
too hot, too cold, chemical fumes etc. fails
earlier.

4. For transformers moisture in oil reduces

insulation strength of oil, paper & enamel.

It also forms sludge in the oil Which settles

at the bottom blocking the free passage of oil
& rise in operating temperature.
5. Greater the load on the machine higher
will be its operating temperature and
shorter will be its life.
It is the operating temperature which
decides the life of the machine.

10 C rise in operating temperature reduces

the life of machine by 10%

The life expectancy of the machine

reduces by half for every 100 C rise of
temperature.
Indian Standards Institute
(the former name of the BIS)
Testing of power Transformers
IS 2026
 Bureau of Indian Standards (BIS)

ISI mark is a certification mark for industrial products

in India.

The mark certifies that a product confirms to the Indian

Standard, mentioned as IS:xxxx on top of the mark,
developed by the Bureau of Indian Standards (BIS),
the national standards body of India.

The ISI mark is mandatory for certifying products to be

sold in India.
It is very common in India to find products with
unreal ISI marks, i.e. affixing ISI marks on the
product without actually getting certified.
Fake ISI marks usually do not carry

(i) the mandatory 7-digit license number(written

as CM/L-xxxxxxx) required by BIS.

(ii) IS number on top of the ISI mark which

signifies the number of the Indian Standard for
the particular product.
This is a punishable offense by the law, but the
practice is common.
The BIS describes various standards for the
machine/equipment manufactured
Testing of machine/equipment shall be done as
per the IS code
The IS code specifies ….
Scope/limitation of the code
Various definitions / technical terms
Operating conditions
Various tests to be conducted
Procedures to conduct the test
Tolerances
Calculating & interpreting the results
Graphical representation of results
 Significance of maintenance

A properly organised good maintenance will….

 Reduce the chances of fault occurrence which

Increases the life & reduces the down period
of machine/equipment.
 Provide planned shut down during the period
of inactivity or least usage for the purpose of
major overhauls.
 Ensure continuity of operation & reduces
danger of breakdowns in peak loads.
 Detect troubles in the early stages &
corrective actions can be taken before
breakdown
 Types of maintenance

1. Routine maintenance

2. Preventive maintenance

3. Breakdown maintenance
 1. Routine maintenance

It is the maintenance which is scheduled to be

carried out (mostly) daily.
It includes….

 Cleaning the dust by blowers

 Recording load current, voltage,
temperature.
 Oiling, greasing
 Checking the noise level
 Tightening the end connections
 Checking vibrations.
 Checking oil level of transformer & breather.
 2. Preventive maintenance

It is the planned & organised schedule of

maintenance which is to be carried out in order
to avoid the breakdowns.
It may be weekly, fortnightly, monthly, quarterly
or yearly.

It includes….

o inspection of loose parts

o Ventilation, oiling , greasing
o Repairs or replacement of wearied out parts
 3. Breakdown maintenance
It is to be carried out immediately when the
breakdown occurs.
The breakdown may be due to short circuit fault
in winding, earth fault, failure of bearing in rotary
machine.
In this type of maintenance Immediate steps are
taken to remove the fault.
It includes rewinding, replacement of bearings
Corrective steps such as checking of…
1. The tightness of stationary parts
2. Free movements of rotating parts
3. The reasons for occurrence of fault
4. Atmospheric conditions
are taken to avoid future failures.
 Total productive maintenance (TPM)

It is a system of maintaining and improving the integrity

of production and quality systems through the
machines, equipment, processes, and employees that
add business value to the organization
One of the main objectives of TPM is to increase the
productivity of plant and equipment with a modest
investment in maintenance
In order for TPM to be effective, the full support of the
total workforce is required. This should result in
accomplishing the goal of TPM: Enhance the volume
of the production, employee morale and job
satisfaction.
 Eight pillars of TPM

1. Continuous improvement (Kaizen)

2. Autonomous maintenance (hozen)
3. Planned maintenance (hozen)
4. Quality maintenance (hozen)
5. Operation & maintenance
skill development (Training)
6. Initial phase system control
(Development management)
7. Safety, health & environment
8. Office TPM
Total productive maintenance (TPM)
FACTORS AFFECTING PREVENTIVE
MAINTANANCE SCHEDULE

At a particular time of year the industry is

heavily loaded while for other period it is
lightly loaded and the maintenance can be
carried during this period of time.
At a particular time the production is most
urgent and profitable than the cost of
breakdown & down period of machine.
Some times the cost of maintenance is
more than cost of replacement
FACTORS AFFECTING PREVENTIVE
MAINTANANCE SCHEDULE

Whether the location or position of

machine to be maintained is easily
accessible or not.
The age of machine also affects the
schedule.
The policy of replacement in the industry.
 FACTORS AFFECTING PREVENTIVE
MAINTANANCE SCHEDULE

1. Mode of operation of plant

2. Cost of plant outage due to failure against
cost of maintenance
3. Consequence of outage
4. Cost of standby machine or equipment
5. Access to machine for carrying out
maintenance
6. Likelihood of failure
7. Replacement strategy
PROCEDURE FOR DEVELOPING
PREVENTIVE MAINTENANCE SCHEDULE

The maintenance schedule should not be very

Rigid and shall suit all the circumstances, hence
the schedule developed should be based on the
experiences. While planning the schedule
following points are to be considered…
• Importance of machine
If the machine fails how much will be the loss
due to down period.
PROCEDURE FOR DEVELOPING
PREVENTIVE MAINTENANCE SCHEDULE
• Duty cycle of machine
Whether the machine is working continuously or
otherwise
• Age of machine
For old machines whether the cost of repairs is
more than cost of replacement.
• Over loads & other service conditions
If the machine is continuously overloaded or
operating in severe atmospheric conditions such
as temperature, dust, dirt, chemical fumes,
moisture etc. They required to be maintained
earlier.
 Objectives of Testing
1. To check the physical dimensions of machine as
per design data :
when the machine is manufactured as per a
particular design it is necessary to determine
whether the machine confirms as per designed
data. If not how much is the variation and
whether the variation is within permissible limits
as specified by BIS.
2. Performance of machine as per design
If the variations in results such as efficiency,
regulation, iron losses, copper losses , no load
current , no load speed are not within
permissible limits , then reasons for higher/lower
values are to be investigated and the
manufacturing process is modified accordingly.
 Objectives of Testing

3. To identify existence of any

defects before commissioning &
during operations
4. The purpose of testing can be
quality assurance, improve the
quality of product
5. To analyse that the product is as
per requirements
 Categories of Testing

1. Routine tests
The tests that are conducted on each and every
machine after manufacturing to confirm various
physical parameters as well as the performance
2. Type tests
The tests that are conducted on a sample
machine arbitrarily selected from the a lot/batch
of manufactured machines.
3. Special tests
The tests which are conducted on a machine
when demanded by the customer
 Tolerance
It is the permissible variation in the
physical dimensions, performance,
characteristics of a machine with
which the machine works without
any damage.
 Methods of Testing

1. Direct Testing
The machine under test is directly
loaded. The load could be either
brake arrangement or coupling
with calibrated machine.
2. Indirect Testing
The machine is run on No load &
the data available is used to
predict the performance.
 Methods of Testing

3. Regenerative Testing
The two identical machines are
used. Output of one machine is fed
to input the other machine hence
The power required to be taken
from mains is to overcome losses
in both machines.
 Ingress Protection

Ingress protection ratings or IP ratings,

sometimes interpreted as International
Protection marking, refer to the level of
protection offered by an electrical enclosure,
against solids and liquids.
In an environment where dust or water
could damage electronic components, a
sealed enclosure is used to prevent
such ingress and safe house the electronics.
 Third digit:
First digit: Second digit: Additional
Mechanical
IP indication Solid particle Liquid ingress letter: Other
impact
protection protection protections
resistance
Single Single
Single
IP numeral: 0–6 numeral: 0–9 Single letter
numeral: 0–9
or "X" or "X"
No longer
Mandatory Mandatory Mandatory Optional
used
The standard aims to provide users more detailed information
than vague marketing terms such as waterproof.

For example, a cellular phone rated at IP68 is "dust resistant" and

can be "immersed in 1.5 meters of freshwater for up to 30
minutes".

Similarly, an electrical socket rated IP22 is protected against

insertion of fingers and will not be damaged or become unsafe
during a specified test in which it is exposed to vertically or nearly
vertically dripping water.

IP22 or IP2X are typical minimum requirements for the design of

electrical accessories for indoor use.
 First digit: Solid particle protection
Level Effective
Description
sized against
X means there is no data available to specify a protection
X —
rating with regard to this criterion.
0 — No protection against contact and ingress of objects
>50 mm Any large surface of the body, such as the back of a hand,
1
2.0 in but no protection against deliberate contact with a body part
>12.5 mm
2 Fingers or similar objects
0.49 in
>2.5 mm
3 Tools, thick wires, etc.
0.098 in
>1 mm
4 Most wires, slender screws, large ants etc.
0.039 in
Ingress of dust is not entirely prevented, but it must not enter
Dust
5 in sufficient quantity to interfere with the satisfactory
protected
operation of the equipment.
No ingress of dust; complete protection against contact
6 Dust-tight (dust-tight). A vacuum must be applied. Test duration of up to
8 hours based on airflow.
 Second digit: Liquid ingress protection
Protection
Level Effective against Details
against
X means there is no data
available to specify a
X — —
protection rating with regard
to these criteria.
0 None — —
Dripping water (vertically
falling drops) shall have Test duration:
no harmful effect on the 10 minutesWater equivalent
1 Dripping water specimen when mounted to 1 mm (0.039 in) rainfall per
in an upright position onto minute
a turntable and rotated at
1 RPM.
Vertically dripping water
shall have no harmful Test duration: 2.5 minutes for
Dripping water effect when the enclosure every direction of tilt (10
2 when tilted at is tilted at an angle of 15° minutes total)
15° from its normal position. A Water equivalent to 3 mm
total of four positions are (0.12 in) rainfall per minute
 Second digit: Liquid ingress protection

Protection
Level Effective against Details
against
Water falling as a spray at
any angle up to 60° from
the vertical shall have no
harmful effect, utilizing For a spray nozzle:Test
either: a) an oscillating duration: 1 minute per square
fixture, or b) A spray meter for at least
nozzle with a 5 minutes[4] Water volume: 10
counterbalanced liters per minute
3 Spraying water shield.Test a) is conducted (0.037 impgal/s) Pressure:
for 5 minutes, then 50–150 kPa (7.3–21.8 psi)
repeated with the For an oscillating tube: Test
specimen rotated duration: 10 minutes Water
horizontally by 90° for the volume: 0.07 liters per minute
second 5-minute test. Test (0.00026 impgal/s) per hole
b) is conducted (with
shield in place) for 5
minutes minimum.
 Second digit: Liquid ingress protection

Protection
Level Effective against Details
against
Water splashing against
the enclosure from any
direction shall have no
harmful effect, utilizing
Oscillating tube: Test duration
either:a) an oscillating
Splashing of 10 minutes, or spray nozzle
4 fixture, or b) A spray
water (same as IPX3 spray nozzle
nozzle with no shield. Test
with the shield removed)
a) is conducted for 10
minutes. b) is conducted
(without shield) for 5
minutes minimum.
Test duration: 1 minute per
Water projected by a
square meter for at least
nozzle (6.3 mm (0.25 in))
3 minutesWater volume:
5 Water jets against enclosure from
12.5 litres per minute
any direction shall have no
Pressure: 30 kPa (4.4 psi) at
harmful effects.
distance of 3 meters (9.8 ft)
 Second digit: Liquid ingress protection

Protection
Level Effective against Details
against
Test duration: 1 minute per
Water projected in
square meter for at least
powerful jets (12.5 mm
3 minutesWater volume: 100
Powerful water (0.49 in)) against the
6 liters per minute
jets enclosure from any
(0.37 impgal/s) Pressure:
direction shall have no
100 kPa (15 psi) at distance
harmful effects.
of 3 meters (9.8 ft)
Water projected in
powerful jets (6.3 mm
Test duration: at least
(0.25 in) nozzle) against
Powerful water 3 minutes[citation needed]
the enclosure from any
jets with Water volume: 75 liters per
6K direction, under elevated
increased minute (0.27 impgal/s)
pressure, shall have no
pressure Pressure: 1,000 kPa (150 psi)
harmful effects. Found in
at distance of 3 meters (9.8 ft
DIN 40050, and not IEC
60529.
 Second digit: Liquid ingress protection

Protection
Level Effective against Details
against
Ingress of water in harmful Test duration:
quantity shall not be 30 minutes.[2]Tested with the
possible when the lowest point of the enclosure
Immersion, up
enclosure is immersed in 1,000 mm (39 in) below the
7 to 1 meter (3 ft
water under defined surface of the water, or the
3 in) depth
conditions of pressure and highest point 150 mm (5.9 in)
time (up to 1 meter (3 ft below the surface, whichever
3 in) of submersion). is deeper.
 Second digit: Liquid ingress protection

Protection
Level Effective against Details
against
Protected against close-
range high pressure, high-
temperature spray
downs.Smaller specimens
rotate slowly on a
turntable, from 4 specific Test duration: Fixture: 30 sec.
angles. Larger specimens in each of 4 angles (2 min.
are mounted in the total), Freehand: 1 min/m2, 3
intended position when min. minimumWater volume:
Powerful high- being used, no turntable 14–16 liters per minute
9K temperature required, and are tested (0.051–0.059 impgal/s)
water jets freehand for at least 3 Pressure: 8–10 MPa (80–
minutes at a distance of 100 bar) at distance of 0.10–
0.15–0.2 meters (5.9 in– 0.15 meters (3.9 in–5.9 in)
7.9 in). Water temperature: 80 °C
The specific requirements (176 °F)
for the test nozzle are