Case studies

3-Phase Induction Motor Dynamic Testing

Our Customer’s Challenge

Spalding Power Station purchased a 6.6kV, 3.6MW spare motor for a critical plant application, which had been stored until required. After a routine maintenance swap, the motor exhibited high vibration from startup, even when decoupled from the pump. Onsite diagnostics confirmed the issue lay with the motor.

Due to it’s size and the need to replicate site conditions, the client sought independent testing. With OEM support unavailable, Quartzelec Rugby was chosen for its ability to test motors up to 13.8kV and to simulate the full load conditions for this motor, ensuring accurate fault diagnosis and future reliability.

The Quartzelec Solution

Initial static electrical tests, performed in the motor’s ‘as received’ condition, confirmed suitability for further testing. Insulation Resistance (IR) values exceeded minimum criteria, and stator winding resistances were balanced across phases.

The motor then underwent revalidation as a precaution, including a light run and a FSC heat run, to ensure that it could operate safely at it’s rated output for future operation. Dynamic testing was also conducted - following in-house procedures - for motors of this size and voltage.

A light run verified mechanical stability, with bearing temperatures recorded and phase rotation and magnetic centre confirmed satisfactory. A FSC heat run at nominal stator current ensured stator winding temperatures stabilised, with cooling water temperatures monitored.

Vibration measurements were then taken on all bearing housing planes which allowed the customer to pinpoint the root cause of the problem experienced at site. Then with final static electrical tests providing good results, the motor was deemed fit for continued operation and ready for return to service

Key Benefits

Comprehensive Testing and Validation: Ensures motors are thoroughly assessed for safe and reliable operation under realistic conditions
Specialised High-Voltage Capability: The ability to test motors up to 13.8kV and conduct FSC testing for motors above 1MW allows replication of demanding site applications
Detailed pre- and post-testing procedures, for both electrical and mechanical parameters provide a clear and reliable diagnosis of any motor issues, leading to targeted solutions
Enhanced Reliability and Operational Safety: Rigorous revalidation processes ensure motors meet all performance standards

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