SURGE TESTING

Educational Series: Why Test?

Why Do Motors Fail? The cost of motor failure is measured by In some cases if the two waves separate
interruption of plant output as well as as the test voltage is increased, this
Motors fail both mechanically and extent of repair or replacement. Surge indicates weakened insulation which in
electrically. Electrical failure occurs due testing greatly decreases both. It detects time will lead to electrical failure.
to shorting which is caused by a failure early enough so that repair or
breakdown of winding insulation. There replacement can be scheduled during a Surge Scope Patterns of Two Coils
are three types of insulation failure that normal shutdown rather than an
can occur: emergency outage. In addition, damage to
yyGround wall insulation (the primary the motor is minimized.
insulation between the copper winding How is Surge Testing Performed?
and steel core)
The test can be performed on the motor Good Deteriorating
yyPhase-to-phase insulation (the winding without actually connecting to Insulation Insulation
secondary insulation between the end the motor itself. The test equipment can
turns of a random wound motor) be connected to the load side of the When Should Surge Testing be
yyTurn-to-turn insulation (the secondary motor starter. During the test a voltage Performed?
insulation applied to the surface of the pulse is placed across two of the three
windings while the third is grounded. The Surge testing is a part of a comprehensive
copper winding)
magnitude of the pulse is approximately maintenance program. Without
Stresses that cause electrical motor twice the operating voltage plus 1000 maintenance and repair all motors will
failure include differential thermal stress, volts. Therefore, low voltage starters eventually fail either electrically or
different coefficients of expansion, varnish operating at 460 volts, are tested at mechanically. A complete maintenance
weakening at high temperatures, approximately 2000 volts and medium program will reduce any unexpected
magnetic force due to winding currents, voltage starters, operating at 2400 volts, occurrences. Surge testing will predict
environmental contaminants, and are tested at approximately 6000 volts. motor burn-out due to turn-to-turn or
moisture. These stresses cause looseness, Pulses are produced at a frequency of 60 phase-to-phase shorting.
motion, and wear of the insulation. times per second and dissipate in
Surge testing should be added to a
approximately 100 microseconds.
Why Perform Surge Testing? regular predictive maintenance program.
The output, which is a dampened sign It should be used in conjunction with high
Insulation deterioration is one of the wave, is then monitored on an potential or insulation resistance testing
first signs that a motor is going to fail oscilloscope. Since all three windings of the primary insulation as well as
electrically. Since secondary insulation should have the same surge patterns, the mechanical evaluation such as
is least able to sustain wear, shorting two patterns being monitored should vibration analysis.
usually occurs here before the thicker, appear as a single overlapping wave. This
ground wall insulation is affected. Surge procedure is repeated for all three pairs
testing is a non-destructive test and of windings.
detects the early stages of secondary
insulation deterioration.

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YT-02-07 (R5/17) 1