Implementation
Houghton International was initially contracted to carry out onsite electrical, mechanical and visual inspections on 4 motors. A range of testing was provided including phase resistance and inductance, insulation, resistance and polarisation index (IR/PI), HiPot, surge and partial discharge (PD) testing. During testing, engineers found low PI readings on the motor, a potential sign of contamination or insulation degradation. The site team recommended the motor be transported to Houghton International for a more in depth inspection.
Overhaul
Bearing checks and a visual check for signs of contamination or partial discharge were carried out, one of the inspections revealed signs of overheating and corona discharge. The site team recognised these as an early indication of HV electrical insulation deterioration that would ultimately lead to machine failure. A full rewind was recommended and carried out and new and spare bearings were manufactured and supplied before being returned to the site and recommissioned.
Outcome
Conducting a wide range of tests allows engineers to build a better picture of the condition of the machinery. Standard onsite tests such as phase resistance and inductance are useful but insufficient for finding all possible faults in motors. Additional tests requiring specialist equipment and expertise are able to detect turn to turn issues as well as phase to phase and provide more information. Not only does this reduce the risk of unexpected in service failure but it also provides a more thorough baseline for periodic testing and ongoing condition monitoring.
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