Direct mechanical load testing
Herman vd Merwe
(Engineering Manager)
Revision: November 2005
Direct mechanical load testing
HV load test plant of Marthinusen & Coutts, Cleveland
Functionalities and Capacity
•
AC induction & synchronous
motors, DC motors, generators,
MG sets, VSD drives, loads
•
Any popular machine speed
•
LV up to 11 kV / Up to 1800 kW
•
‘Frequency’ starting (large motors)
•
Temperature rise
•
Efficiency, power factor, slip
•
•
Loss separation, locked rotor
torque / current
All routine & QC tests
•
Full PLC / SCADA control
•
Auto generation of test reports
Direct mechanical load testing
Direct mechanical load testing
Mimic panel of the HV load test plant (plant deactivated)
Direct mechanical load testing
Mimic panel of the HV load test plant (plant activated)
Direct mechanical load testing
Mimic panel of the HV load test plant (data capture)
Direct mechanical load testing
Marthinusen & Coutts (Cleveland)
Marthinusen & Coutts (Cleveland)
Magnetising curve of electric motor
Separation of losses for electric motor
** Software: TS/MC, rev 2.0 (Aug '04); In accordance with SABS IEC 34 - 2 **
** Software: TS/SL, rev 2.0 (Aug '04); In accordance with SABS IEC 34 - 2 **
Job number : GF04 XXXX (Customer XXX : 1 600 hp, 6.6 kV, 8 pole, serial # YYY, GEC)
Job number :
Current (A) Voltage (kV)
40.1
6.60
34.8
6.00
28.9
5.20
26.4
4.79
22.7
4.19
19.7
3.62
GF04 XXXX
(Customer XXX : 1 600 hp, 6.6 kV, 8 pole, serial # YYY, GEC)
kV^2 Total NL loss (kW) Voltage (kV) Current (A)
43.56
11.10
6.60
40.1
36.00
9.60
6.00
34.8
27.04
8.74
5.20
28.9
22.94
7.89
4.79
26.4
17.56
7.38
4.19
22.7
13.10
6.66
3.62
19.7
Correlation
Stator copper loss (kW) I, F & W (kW)
0.85
10.25
0.64
8.96
0.44
8.30
0.37
7.52
0.27
7.11
0.20
6.46
99.29%
F & W @ wn (kW)
4.91
I @ Vn (kW)
5.34
6
5
4
3
2
1
0
0
5
10
15
20
25
30
35
40
45
No-load current (A)
Iron, friction & windage loss (kW)
Motor supply voltage (kV)
7
12
10
8
6
4
2
0
0
5
10
15
20
25
30
35
40
Voltage^2 (kV^2)
Comments:
The level of saturation of the magnetic material in this motor is low. As a direct result of this, the iron loss of the
motor is low (refer to the "Separation of losses for electric motor" test certificate). This is one of the reasons for
the very high efficiency of this motor (refer to the "Motor efficiency and power factor curves" test certificate).
Comments:
The iron loss of the motor is low.
Refer to the comments made in the "Magnetising curve of electric motor" test certificate.
Test conducted by: John Gajdus
Approved by: Herman van der Merwe
(Engineering Manager)
Test date: September 06, 2004
Date: September 08, 2004
Test conducted by: John Gajdus
Test date: September 06, 2004
Approved by: Herman van der Merwe
(Engineering Manager)
Date: September 08, 2004
45
50
Direct mechanical load testing
Marthinusen & Coutts (Cleveland)
Marthinusen & Coutts (Cleveland)
Determination of electric motor efficiency by summation of losses
Motor efficiency and power factor curves
** Software: TS/EF, rev 2.0 (Aug '04); In accordance with SABS IEC 34 - 2 **
** Software: TS/CU, rev 2.0 (Aug '04); In accordance with SABS IEC 34 - 2 **
Job number:
Job number:
GF04 XXXX (Customer XXX : 1 600 hp, 6.6 kV, 8 pole, serial # YYY, GEC)
Type of load run :
Short duration.
Load point 1 (circa 100% of rated load)
Stator winding phase resistance (ohm) / at winding temperature (degC) :
Stator winding phase resistance (ohm) / at corrected temperature (degC) :
0.176
0.2192
/
/
14
75
GF04 XXXX
Test date: September 06, 2004
(Customer XXX : 1 600 hp, 6.6 kV, 8 pole, serial # YYY, GEC)
Load point # Load (% of rated output power) Efficiency Apparent power (kVA) Real power, input (kW)
4
25.3%
95.7%
586.00
315.00
3
51.5%
97.2%
828.00
632.00
2
79.4%
97.2%
1 150.00
975.00
1
102.4%
97.0%
1 460.00
1 260.00
Constant losses:
5.34 Iron loss, at rated voltage (kW)
4.91 Friction & windage loss, at full speed (kW)
10.25 Total constant losses (kW)
Power factor
0.538
0.763
0.848
0.863
Motor efficiency for various load points
100.0%
99.5%
99.0%
Stator current drawn at load point (A)
Input power absorbed at load point (kW)
Rotor speed, measured at load point (rpm)
Supply frequency (Hz)
Number of poles of motor
Rated output power of motor (kW)
Speed of rotating field of motor (rpm)
Rotor slip at load point (p.u.)
Power transmitted to rotor (kW)
Efficiency
Load losses:
129.8
1 260.00
744.0
50
8
1 193.60
750
0.00800
1 243.58
98.5%
98.0%
97.5%
97.0%
96.5%
96.0%
95.5%
11.08 Stator copper loss, at reference temperature (kW)
9.95 Rotor copper loss (kW)
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100% 110%
90%
100%
Load (% of rated output power of motor)
21.03 Total load losses (kW)
Additional / stray load losses:
6.30 (kW)
Motor power factor for various load points
TOTAL LOSS:
37.58 (kW)
1.00
0.90
Motor output power at load point:
1 222.42 (kW)
102.4% (% of rated output power)
Power factor
0.80
Motor efficiency at load point:
97.0%
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
Test conducted by: John Gajdus
Test date: September 06, 2004
0%
10%
20%
30%
40%
50%
60%
70%
80%
110%
Load (% of rated output power of motor)
Comments:
The design of this motor optimises efficiency at a load point of circa 70% (rather than 100%) of rated output power.
Approved by: Herman van der Merwe
(Engineering Manager)
Date: September 08, 2004
This is done by keeping the constant / no-load losses in the motor low (refer to the "Magnetising curve of electric motor"
test certificate. The power factor of the motor is considered to be normal to high.
Direct mechanical load testing
Marthinusen & Coutts
driven by an OEM approach.
partners in asset management.
S.H.E.Q. POLICY
DOC No: R101
Driefontein
TIME
AMBIENT
09h45
10h00
10h15
10h30
10h45
11h00
11h15
14.5
14.9
15.1
15.1
15.2
15.3
15.9
DOCUMENT & DATA CONTROL
REV: 02
Page 1 of 1
Issue Date: 12/03/02
TESTED BY:
Dennis Michas
NAME
53 Hospital Str, Cleveland, Johannesburg
Job No.:
DE BEARING NDE BEARING
13.6
15.8
17.9
20.4
22.3
24
24.5
Pty (Ltd)
Reg. No. 1954/02996/07
Doc.no.R/009
partners in asset management.
A.C. Inspection / Test Report
CUSTOMER:
JOB No.:
Make:
Type:
hp:
Phase:
Exc. Volts:
Serial No.:
Frame No.:
Volts:
rpm:
Rotor Volts:
kW:
Hz:
Exc. Amps:
Encl.:
Amps:
Rating:
Rotor Amps:
GF052657
T DE
T NDE
13.5
15.6
18.1
20.7
22.6
24.1
24.7
ELECTRICAL TESTS
PRE VARNISH
FIRST CORE TEST
SECOND CORE TEST
Insulation Resistance @
M↓
M
Phase Resistance @
R-Y
Y-B
B-R


Pressure Test @
kV
Interturn
Polarity Test
V
A
Voltage Applied to attain FLC:
R
Name:
Sign:
DATE:
12/07/2005
SIGNATURE
PO Box 40018, Cleveland, 2022
driven by an OEM approach.
Reg. No. 1954/02996/07
BEARING TEMPERATURE LOG SHEET
Customer:
Marthinusen & Coutts
Pty (Ltd)
Tel: +27 11 616 2320
Fax: +27 11 615 4727
DIRECTORS: R Spoon (Chairman), G Garland (Managing), AD Vosloo, D Liebenberg, HG Marthinusen, BR Wright, BG Hitchcock
A
Y
A
B
Date:
PRELIM
Pass Fail
Pass Fail
Vdc
between
°C

Pass Fail
Pass Fail
Pass Fail
V
A
ELECTRICAL TESTS
PRE VARNISH
FIRST CORE TEST
SECOND CORE TEST
Insulation Resistance @
M↓
M
Phase Resistance @
R-Y
Y-B
B-R


Pressure Test @
kV
Interturn
Polarity Test
V
A
Voltage Applied to attain FLC:
Salient Pole / Volt Drop
R
A
Y
A
B
Name:
Sign:
Date:
PRELIM
Pass Fail
Pass Fail
Vdc
between
°C

Pass Fail
Pass Fail
Pass Fail
V
V
A
PASSED FOR RUN TESTING
RUN TESTING (NO LOAD)
Insulation Resistance @
Vdc Starting Torque (Locked Rotor)
Δ
Y
M↓
M between
Volts Applied
V
Pressure Test @
kV Pass Fail Torque Arm NA
mts Scale Reading
NA
kg
ELECTRICAL / MECHANICAL INSPECTION AFTER TESTVolts Applied
V
Component
Rec. Fitted Component Rec. Fitted No Load Amps:
R
Y
B
N/Plate Details
S/R Cover
Rotor Volts:
V
V
V
Brush Grade
T Box
RPM
D.E.
T Box Gaskets
T Box Cover
Motor run for
HR
Rotation
Lead Marking
Lead Lugs
Bearing Temp. [°C]: Amb.
D.E.
N.D.E.
Airgap Plugs
M
Brg. Temp. Mon
End Play
mm Final I.R.
R/Shaft Lock
Paint Color
Vibration Measurement mm/s
Air Gaps
Gauge Glass
Documents
DE NDE DE
NDE
Horizontal
Final Inspec.
Vertical
Heaters
Value =
DE
DE
Axial
PT100
Value =
Name:
Thermisters
Value =
NDE
NDE
Name:
Sign:
Sign:
Date:
Date:
DE
NDE
CUSTOMER WITNESS
FINAL INSPECTION PASS FOR DESPATCH
Name:
Name:
Sign:
Sign:
Date:
Date:
COMMENTS