Method Statement

The Insulation Resistance Testing ensures the healthiness of windings of

Motors/Generators against factors like moisture, high temperature and
impurities in order to avoid damage to the insulation.

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 Introduction:
Insulation Resistance Test

The IR test measures the resistance of the electrical insulation between the copper conductors and the core
of the stator or the rotor. Ideally, this resistance should be infinite because, after all, the purpose of the
insulation is to block current flow between the copper and the stator core. In practice, the IR is not infinitely
high. Usually, the lower the IR, the more likely it is that there is a problem with the insulation. The PI test is a
variation of the IR test. According to ANSI/AR100-2015 and IEEE 43-2013 for motors & generators testing; PI
is the ratio of the IR measured after voltage has been applied for 10 min (R10) to the IR measured after just
1 min (R1), that is

An advantage of the index ratio is that all of the variables that can affect a single mega ohm reading, such as
temperature and humidity, are essentially the same for both the 1 min and 10min readings.

Polarization Index = 10 min Insulation resistance (Meg-ohm) reading /1 min Insulation resistance (Meg-ohm)
reading

ANSI/AR100-2015 and IEEE 43-2013 Standard recommendations for Test Voltages:

IR Measurement Test Voltages

Rated Voltage of Motor (V) DC Voltage to be applied
<1000 500
1000-2500 500-1000
2501-5000 1000-2500
5001-12000 2500-5000
>12000 5000-10000
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Note:
A temperature correction factor may be applied to correct the megohm measurement at present
temperature to what it would be at a standard temperature of 40°C per IEEE 43 and ANSI/EASA standards.

Factors Affecting Insulation Resistance Readings:

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 There are a number of things that affect current, including temperature of the insulation and humidity, as
mentioned in the previous section. Right now, let’s just consider the nature of current through insulation
and the effect of how long voltage is applied. Current through and along insulation is made up partly of a
relatively steady current in leakage paths over the insulation surface. Electricity also flows through the
volume of the insulation.
There are a number of things that affect current, including temperature of the insulation and humidity, as
mentioned in the previous section. Right now, let’s just consider the nature of current through insulation
and the effect of how long voltage is applied. Current through and along insulation is made up partly of a
relatively steady current in leakage paths over the insulation surface.

1 A Capacitive Current.

When a DC voltage is applied to a capacitor, a high charging current first flows, which then decays
exponentially. The size of the capacitor and the internal resistance of the voltage supply, typically a few
hundred kilohms, set the current decay rate. A form-wound stator coil may have a geometric capacitance of
about 1 nF between the copper and the core. A large hydro generator may have a capacitance of 1 μF. Thus,
this current effectively decays to zero in less than 10 s. As this capacitive current contains little diagnostic
information, the initial IR is measured once the capacitive current has decayed close to zero. This time has
been set as 1 min to ensure that this current does not distort the IR.

2 A Conduction Current.

This current is due to electrons or ions that migrate across the insulation bulk, between the copper and the
core. This is a galvanic current through the groundwall. Such a current can flow if the groundwall has
absorbed moisture, which can happen in the older thermoplastic insulation systems, or if a modern
insulation has been soaked in water for many weeks. This current also flows if there are cracks, cuts, or
pinholes in the ground insulation (or magnet wire insulation in random-wound machines), and some
contamination is present to allow current to flow.

3 Leakage Surface Current.

This2660;
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contamination (oil or moisture mixed with dust, dirt, fly ash, salt, chemicals, etc.) on the surface of the
windings. Ideally, this leakage current is zero. However, if this current is large, it is likely that contamination-
induced deterioration

4 The Absorption Current.

This is a current that is hard to conceptualize. The current is partly due to the reorientation of certain types
of polar molecules in the applied DC electric field. Many practical insulating materials contain polar
molecules that have an internal electric field due to the distribution of electrons within the molecule.

Testing Equipment:
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 Megger S1-1068

TEST Procedures:

IR & PI tests shall be done simultaneously. If the winding temperature is below the dew point, the winding
may be heated to dry off the moisture that has condensed on the winding. If the temperature is below the
dew point, there is no way to correct the IR & PI for humidity Otherwise, the test is very simple. The
procedure is as follows:

 Remove all external connections to the machine and completely discharge the windings to the
grounded machine frame.
 Apply required DC voltage between the winding and ground using a direct indicating, Insulation
Resistance Tester (S1-1068).
 Continue to apply the voltage for 10 minutes. Measure the insulation resistance after 1 minute and
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minutes.
 Switch off supply to the meter and completely discharge the windings to the grounded machine
frame.
 Calculate the polarization index by dividing the 10-minute insulation resistance by the 1-minute
insulation resistance.
 Note the winding temperature.

If test is carried out only on one winding of three phase equipment, then other windings should be
grounded during the test.

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 Other useful recommendations

 Before starting a test, the winding insulation should be discharged to avoid measurement errors.
 For machines with a stress-control coating applied to the end-windings, there may be an increase in
the surface leakage current and thereby lower megohms than expected.
 For winding temperatures below the dew point, it is impossible to predict the effect of condensation
on the surface. Therefore, a correction to 40 °C for trend analysis will introduce significant errors.
 A minimum discharge time of four times the voltage application duration is recommended..
 Absorption discharge: This decay may take more than 30 min depending on the insulation type and
physical size of the DUT.
 A significant decrease in insulation resistance (increase in measured current) with an increase in
applied voltage may be an indication of insulation problems in an insulation resistance test.
 For tests conducted under similar conditions, a steady increase in the IR with age, (decrease in
absorption current) may indicate decomposition of the bonding materials, especially when the
insulation materials are of the thermoplastic type.
 When a low PI occurs at temperatures above 60°C, a second measurement below 40°C and above
the dew point is recommended as a check.
 PI can be used to indicate when the drying process of insulation may be terminated. This would be
when the PIhas exceeded the recommended minimum.
 If the IRvalue (at 40 °C) is greater than 5000 MΩ, the PI may be ambiguous and can be disregarded.

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