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BRIEF TEST PROCEDURE FOR AC GENERATORS
Prepared by: R.Stanley Date: 24.03.2005
ROUTINE TEST
SL.NO TEST PROCEDURE REF.STANDARD
1.1 Resistancemeasurement on mainstator, exciter statorand exciter rotor.Resistance of
windings is measured by using Kelvinbridge/micro ohmmeter and resistance of
accessories like RTD,BTD, ATD, and space heater by using digital multi meter.Ambient
temperature is also recorded.IEC 34/ IS 47221.2a.1.2b.Insulation resistancetest
before and afterHV test on mainstator, main rotor,exciter stator andexciter
rotor.Polarization IndexTest.a) Insulation res. of winding and space heater ismeasured
w.r.t to earth by using a meggar (500 V forLT, 1000 V for HT).b) Insulation
resistance of stator winding using 1000 Vmeggar. The value recorded at the end of
1minuteand 10 minute. PI value of the machine = 10 minutevalue / 1 minute value.IEC
34/ IS 47221.3 High voltage test onmain stator.High voltage of 23 KV (i.e. Twice the
rated voltage + 1 KV) isapplied between each phase and ground, the other
twophases are connected to ground. Test is conducted for 1minute for each phase.IEC
34/ IS 47221.4 High voltage test onmain rotor, exciterstator and rotor.High voltage of
1.5 KV (i.e. Twice the rated voltage + 1 KV) isapplied to windings w.r.t. ground. Test is
conducted for 1minute.IEC 34/ IS 47221.5 Open circuitcharacteristic(shall be done
duringO.C. heat run test 2.2)The generator is run at rated speed from prime mover in
opencircuit condition. Generator voltage, excitation current andvoltage are recorded
from 120% of rated voltage at equalintervals till residual voltage attained.IEC 34/ IS
47221.6 Short circuitcharacteristic (shall bedone during S.C. heatrun test 2.3)The
generator stator terminal is shorted and is run at ratedspeed from prime mover. The
short circuit current reading at25%, 50%, 75% and 100% are taken w.r.t excitation volts
andcurrent.IEC 34/ IS 47221.7 Phase sequence testw.r.t the direction ofrotation
(shall be doneduring O.C. heat runtest 2.2).The generator is run in specified direction at
rated speed inopen circuit condition. The phase sequence meter isconnected to the
generator PT terminal (U, V, W to connectedto R, Y, B of the meter). The direction of
meter is recorded.IEC 34/ IS 47221.8 Voltage balance test(shall be done
duringO.C. heat run test2.2).All the 3 phase voltages are checked for balance in
opencircuit condition at rated Voltage and speed. IEC 34/ IS 47221.9
Vibrationmeasurement test(shall be done duringO.C. heat run test2.2).Generator is run
at rated voltage and speed. Vibration ismeasured at vertical, horizontal and axial
directions on bothDE and NDE bearings.IEC 34/ IS 12075

BRIEF TEST PROCEDURE FOR AC GENERATORS


Prepared by: R.Stanley Date: 24.03.2005
1.10 Shaft voltagemeasurement (shallbe done during O.C.heat run test 2.2).Voltage
induced in between the shaft drive end and non-driveend by using digital
multimeter.IEC 34/ IS 47221.11 Impedance test ofrotorA 1 phase variable voltage
is applied to the rotor field windingand current is measured. Readings are recorded at
25%,50%, 75% and 100% of the rated field voltage.IEC 34/ IS
47221.12 Momentary overloadtest (shall be doneduring S.C. heat runtest 2.3).The
generator is run at rated speed with its stator terminalsshorted. Generator is excited to
150% of the rated current.The condition is passed for 30 seconds.IEC 34/ IS 4722
TYPE TEST
2.1 Mechanical heat runtestThe generator is run at rated speed. In this condition at
equalintervals the power input to prime mover, generator RTD,BTD, ATD, ambient and
body temperature are recorded tillthermal equilibrium is reached. Then machine is
stopped andhot resistance of all windings is measured.IEC 34/ IS 4722/ IS
71322.2 Open circuit heat runtestThe generator is run at rated speed and voltage. In
thiscondition at equal intervals the power input to prime mover,generator voltage, exciter
voltage and current, generatorRTD, BTD, ATD, ambient and body temperature are
recordedtill thermal equilibrium is reached. Then machine is stoppedand hot resistance
of all windings is measured.IEC 34/ IS 4722/ IS
71322.3 Short circuit heat runtestThe generator terminal is shorted and run at rated
speed andrated current. In this condition at equal intervals the powerinput to prime
mover, generator current, exciter voltage andcurrent, generator RTD, BTD, ATD,
ambient and bodytemperature are recorded till thermal stability is reached.Then
machine is stopped and hot resistance of all windings ismeasured.
From the above heat run test readings the temperaturerise of the core and
windings is calculated.
IEC 34/ IS 4722/ IS 71322.4 Efficiency test bysummation of lossesmethodThe prime
mover dc motor power input is measured at

Gen. Running at rated speed at zero excitation.

Gen. Running at rated speed and rated voltage inO.C. condition.

Gen. Running at rated speed and rated current inshort circuit condition.

Prime mover running at rated speed in un coupledcondition.From these readings


efficiency is calculated by summation ofIEC 34/ IS 4722

BRIEF TEST PROCEDURE FOR AC GENERATORS


Prepared by: R.Stanley Date: 24.03.2005
losses method.2.5 Harmonic analysis(shall be done duringO.C. heat run test 2.2)The
generator is run at rated speed and voltage in opencircuit condition, up to 50
th
harmonic is measured with poweranalyser. Then the
THF
is calculated.IEC 34/ IS 47222.6 Noise level test (shallbe done during O.C.heat run
test).Machine is run at rated speed and voltage on no load andnoise is measured at
different locations of the machine at 1mt. Distance using noise level meter. Then the
machine isstopped and background noise level is measured. From theboth values the
noise level of machine is calculated.IEC 34/ IS 120652.7 Over speed test (shallbe
done duringmechanical heat runtest 2.1).The generator is run at 120% of rated speed
for 2 minutes, noabnormalities should be noticed during testing.IEC 34/ IS
47222.8 Wave formmeasurement (shallbe done during O.C.heat run test
2.2)Machine is run at rated speed and voltage. The sine wave ofthe 3 phase voltage is
recorded by using C.R.O.IEC 34/ IS 4722
GENERAL CHECKS
1. Painting thickness.2. Air gap between exciter stator and rotor at different
angles.3. Main and neutral terminal box dimension and suitability for the rated cable
size.4. Auxiliary terminal box dimension, gland plate area suitable for required number
of cables.5. Provision, mounting arrangement and polarity of the neutral side
CTs.6. Foundation dimensions as per drawing.7. Shaft measurement check, key way di
mension check.8. Slip ring and carbon brush check.9. Operational check of
space heaters, local temperature gauges, water leakage detector etc.10. Carbon brush
resistanc