Insulation tests on electric motors and generators: DC

High Potential Testing (HiPot)

electrical-engineering-portal.com/dc-high-potential-testing-hipot-insulation-tests-electric-motors-generators

By Edvard Csanyi November 6, 2023

Why Doing Insulation Testing?

The objective of this technical article is to provide certain criteria and time intervals for
conducting insulation tests on electric motors, generators and other electrical equipment.
Testing is done to ensure that the equipment is intact and to provide a level of confidence
that the insulation will continue to function reliably until the next significant power outage.

Insulation tests on electric motors and generators: DC High Potential Testing (HiPot)

Even if some of the overvoltage test currents are lower than the generally regarded lethal
values, the energy that is stored as charge in the insulating capacitance can be fatal.
Before the device may be said to be dead-dead, the charge that it has stored must first be
discharged, also called “drained.”

Between the thing being tested and the ground in the surrounding area, there is a
dielectric capacitance that stores the charge.

The general rule of thumb is to discharge the system by connecting a low resistance
between the conductors of concern and ground and keeping that connection for at

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least five times longer than the period of the overvoltage test. This should be done at the
very least.
The purpose of this technical article is not to serve as a comprehensive technique for
testing insulation, and it is expected that individuals performing the tests will be
conversant with safety as well as other specific aspects of high-voltage insulation testing.

Table of Contents:

1. Testing integrity of 460V and higher-voltage AC devices

Periodically conducting an insulation megger test at either 500V or 1000V DC is
recommended in order to ascertain whether or not equipment operating at 460V or higher
voltages is reliable. It is recommended that the frequency of testing be based on the site-
specific environmental conditions as well as the expertise gained with the specific
piece of equipment.

In most cases, the time that passes between tests should not be allowed to exceed three
years.

Before applying power to the electrical devices, you need to ensure that it satisfies the
following minimum megohm requirement, which is based on the conditions of operation
and applies to all AC electrical devices with 460 V or greater in voltage. The following
criterion for the test implies that the apparatus being evaluated is kept at a temperature of
25 degrees Celsius.

The results of measurements taken with this method at temperatures higher than 25
degrees Celsius are expected to be conservative.

According to the Institute of Electrical and Electronics Engineers (IEEE) and other
industry standards or recommendations, the minimum insulation megohms to ground for
motors should be 1 megohm per rated phase-phase kilovolt, plus 1 megohm at 40
degrees Celsius. This value should be applied at all temperatures. Testing is used to
determine the insulating megohms, and then those results need to be adjusted for any
temperature variances from the reference temperature of forty degrees Celsius.
The correction factors vary depending on the specific class or kind of insulation. In
general, an increase in temperature leads to a decrease in insulating resistance due to
the greater availability of free electrons for conduction.

The minimum megohms can be estimated to be approximately three times higher at a

temperature of 25°C, which is commonly used as the ambient testing temperature.
Alternatively, for a three-phase test, the minimum megohms can be calculated as three
megohms per kilovolt.

It is customary to conduct ground testing on motors without disrupting the internal

phase connections, as seen in Figure 1.

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Figure 1 – Motor insulation resistance (minimum megohms)

The above motor calculation is often used for other devices in an industrial setting.

In the name of simplicity, it is anticipated that the insulation resistance for a single-phase
test would be three times greater, equivalent to 9 megohms per kilovolt. This
estimation is considered conservative, as it accounts for the presence of phase-to-phase
insulation resistance that diminishes the actual factor, particularly when untested phases
are grounded.

In the case that multiple equipment are being tested concurrently, it may be necessary to
separate or isolate individual equipment units to ensure compliance with the minimum
standards.

The routine insulation testing of electrical equipment units, including buses, cables, circuit
breakers, generators, and transformers, is commonly conducted in the industry using the
motor standard, despite the fact that each type of unit has its own specific minimum
megohms requirement.

Experience has proven that a resistance of three megaohms per kilovolt will not be
an issue for energizing any device, provided that there are no other elements that are
contributing. Utilizing a test equipment that has either 500 or 1000 V DC is the standard
approach.

Consideration should be given to using a 500V test during routine or short outages to
reduce the possibilities of extending the outage for cleaning and dryout, and a 1000V test
should be reserved for overhauls and longer outages where a higher-proof test for an
undefined future life is desired. Here, 1000 V is essentially an overvoltage- or hipot-test
for low-voltage equipment (480V devices).
The common practice in the field is to use 1 megaohm for every kilovolt, which gets rid
of the plus 1 kV, and it does not account for variances in temperature. This is particularly
concerting. When electrical equipment was energized at a resistance of 1 megohm per
kilovolt, numerous reports indicated that it either failed or exploded.

Note that IEEE Standard 43, Testing Insulation Resistance of Rotating Machinery, says
that the needed megohms should be increased by 2 when megger-testing one phase at a
time (with the other two phases grounded), unless guards are used, in which case the
readings should be multiplied by 3, and that this should be done when testing one phase
at a time with a megger.

Suggested Video – “Megger” insulation test on a bad motor

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Watch Video At: https://youtu.be/Fyd3S1EWfYA

The recommendation selected a more straightforward and cautious method of

multiplication by a factor of 3 in both instances, resulting in a value of 9 megohms per
kilovolt at normal temperatures. This criterion is likewise applicable to an entire system or
its constituent components at the level of the apparatus. Put simply, it is permissible to
separate the electrical devices in order to assess their compliance individually.

For instance, the motor can be disconnected from the cables, and if both the cables and
motor satisfy the requirement on their own, they can be rejoined and powered.

Electrical equipment that fails to fulfill the minimum megohm criteria specified above
should undergo cleaning, drying, or refurbishment procedures before being
energized. The utilization of a 10-minute polarization test (PI) on certain equipment can
aid in discerning whether low values are attributable to moisture or alternative forms of
contamination. The PI test involves the division of the 10-minute measurement by the 1-
minute measurement.
Because the voltage being measured is direct current (DC), the capacitive charging
current will decrease as the period of the test goes on, which will result in greater
megohm results.

A PI value of 2 is generally considered to be acceptable in most situations;

however, this is not the case if the equipment has a history of having lower PI
values.

Good Reading – Never let an electric motor drop dead. Learn how to listen and read the
motor’s soul.

Go back to the Contents Table ↑

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2. DC High Potential Testing (HiPot)
During major turbine overhaul outages (HP turbine for cross-compound units), generators
and motors with voltages of 2 kV and above should be routinely overvoltaged tested.
Cables that feed motors are typically included in the overvoltage test for convenience
(motor routine values are not regarded high enough to unduly stress cable insulation).

Otherwise, routine overvoltage testing of wires is not normally advised.

It is impossible to predict whether the equipment insulation will fail during overvoltage
(hipot) testing prior to testing. As a result, while scheduling the test, allow for time to get
materials and repair or replace equipment. However, the routine test values provided in
this technical article for motors and generators are the minimum values (125% instead of
150% maximum) specified by IEEE.

These numbers are regarded strong enough to provide some assurance that the
insulation will not fail before the next severe outage, but not to the extent that they
will cause an unwanted early failure. Higher test values offered for new or refurbished
electrical equipment are based on the assumption that the manufacturer or repair
company is financially responsible for a test failure (under warranty) and may not be
performed if this is not the case.
Before conducting a hipot test on generator and motor stator windings, it is typically
necessary to do a polarization test using a 1000V megger with a polarization index (PI) of
2 or higher. The polarization test, also known as the PI test, refers to the ratio between
the insulation resistance values taken at 10 minutes and 1 minute.

This ratio serves as an indicator of the suitability of the winding for the overvoltage test.

Figure 2 – Generator DC hipot acceptance test

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 Figure 2 – Generator DC hipot acceptance test

A low PI (less than 2) may indicate that cleaning, dryout, or repair is required before the
hipot can be performed.

Nevertheless, it is worth noting that certain insulation systems that are in a satisfactory
state may not provide a Polarization Index (PI) value of 2 or higher. In situations when this
condition is met, and the polarization index (PI) measurement aligns with past
measurements conducted on the specific insulating system, it is permissible to proceed
with the overvoltage testing.

When conducting insulation resistance tests, it is necessary to ensure a minimum

insulation resistance using a 1000V megger. For isolating one phase from the other
phases, as desired for generators and cables, a minimum insulation resistance of 9
megohms per rated kilovolt is required.

On the other hand, when testing all three phases simultaneously, as is done for motors, a
minimum insulation resistance of 3 megohms per rated kilovolt is necessary.

Equipment that reveals megger readings below the specified minimum should not
undergo hipot testing. Equipment that does not reach the minimum suggested megohm
values should undergo drying, cleaning, or refurbishment before undergoing overvoltage
testing.

Important Note!

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The task of conducting overvoltage testing should be exclusively entrusted to technicians
or engineers who possess a comprehensive understanding of the necessary safety
protocols and testing processes, and have received appropriate training to carry out such
testing.

In order to mitigate the financial implications associated with test failures, it is

recommended that the overvoltage testing of generators with a capacity of 10-MVA and
above be conducted under the supervision of experienced supervisors or engineers who
possess relevant expertise in overvoltage testing.

Figure 3 – Generator routine test

Figure 3 – Generator routine test

Note that most generator manufacturers recommend 125-150% of rated kV for

suitability for continued service tests.

Motors and generators are often tested at the starting of an outage to provide time for any
necessary repairs to be completed within the outage timeframe. Furthermore, the testing
should be done while the apparatus is dry (before disassembly or in a cool standby
condition).

Normally, generators are tested fully assembled and under hydrogen pressure (where
applicable). Before performing overvoltage testing on generators with inner water-cooled
stator coils, the water is generally drained by pulling a vacuum to allow megger testing for
an acceptable PI and minimum insulation resistance values.

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Wye-connected generators are generally disconnected at the output and neutral ends, as
seen in Figures 2 and 3 above. To eliminate transient voltages if the test is abruptly
interrupted, each end of the winding is connected with copper bonding wire, and each
phase is individually tested to ground, with the other two phases grounded.

Figure 4 – Motor DC acceptance test

Figure 4 – Motor DC acceptance test

Typically, all three phases of motors lacking neutral leads, which are brought up to the
termination box, are tested concurrently with respect to ground. In typical practice, motors
and their corresponding cables are commonly subjected to joint testing, wherein all three
phases are interconnected and linked together. This testing arrangement is illustrated in
Figures 4 and 5.

The separation of cables from the motor should only be considered when the readings
obtained from the combined motor-cable system are deemed unsatisfactory.

Generators are often subjected to testing using a voltage rise rate or step size of
roughly 2 kV DC, while motors undergo testing with a voltage rise rate or step size of
approximately 1 kV DC. The operator is required to document the measurements of
voltage and current (once they have reached a stable state) for every individual stage. It
is imperative to closely monitor the direct current (DC) and promptly respond if there is an
abnormal increase in current, which suggests an impending insulation failure.
In such cases, it is recommended to terminate the test by gradually dropping the voltage
to zero.

The successful completion of a test is determined by achieving of the recommended

voltage value and the maintenance of a stable current for a duration of one minute. Upon
completion of the experiment, it is imperative to gradually decrease the voltage to zero in
order to prevent abrupt fluctuations and the emergence of potentially harmful transient
voltages.

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Figure 5 – Motor DC routine test

Figure 5 – Motor DC routine test

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3. Generator Rotor Winding Overvoltage Testing

Insulation systems for cylindrical rotor field windings of large generators are typically
subjected to DC overvoltage or hot-pot testing at acceptance values subsequent to
shipment to the site or after onsite rewinds. In such cases, an external party assumes the
cost of repair in the event of a malfunction and must also certify that the apparatus is fit
for service.

An illustration of the test and the recommended DC hipot test values can be found in
Figure 6. In the event that the test is abruptly interrupted, the majority of manufacturers
advise testing at 80% of the factory test value with both ends of the winding shorted
together to reduce transient voltages.

Acceptance testing for a 500V field winding would occur at 6.8 kV DC, as illustrated in the
figure.

Figure 6 – Generator rotor acceptance DC overvoltage testing

Typically, insulation systems for cylindrical rotor field windings of large generators are
subjected to DC overvoltage or hipot testing during the warranty period following one year
of use. In such cases, an external party assumes the financial burden of repair expenses
in the event of a failure and must also certify that the equipment remains fit for continued
operation.

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An illustration of the test and the recommended DC hipot test values can be found in
Figure 7. In the event that the test is abruptly interrupted, the majority of manufacturers
advise testing at 60% of the factory test value with both ends of the winding shorted
together to reduce transient voltages.

After one year of operation, a 500V field winding would be evaluated at 5.1 kV DC, as
illustrated in the figure below.

Figure 7 – Generator rotor first-year warranty DC overvoltage testing

Figure 7 – Generator rotor first-year warranty DC overvoltage

testing

Field windings on cylindrical rotor generators should be tested routinely during unit
overhauls. A PI of 2.0 (measure of moisture or contamination) is typically necessary and
is determined by dividing the megohm reading from ten minutes by the measurement
from one minute.

The exposed insulation for the collector or slip rings on brush machines frequently
accumulates a substantial amount of oil/carbon from the bearings and brushes; therefore,
it may be necessary to perform a thorough cleansing of that region in order to achieve a
satisfactory PI.

The test procedure is illustrated in Figure 8, which recommends the utilization of an

insulation test instrument or a 1000V megger. As illustrated in the figure, the minimum
megohm value is 50, which surpasses the standard nonoverhaul requirement of 4.5
megohms for a 500V field or 9 megohms per kilovolt.

This can be accomplished using a test instrument or a 500V meter.

Figure 8 – Generator rotor routine overhaul insulation testing

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 Figure 8 – Generator rotor routine overhaul insulation
testing

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4. Generator-Neutral Buses or Cables

During generator stator overhauls, the generator-neutral bus and/or cable to the
grounding transformer should be disconnected at both ends and DC high-pot-tested at
the generator stator’s routine value.

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5. Testing Cables (5 kV and Higher)

Cables with voltage ratings of 5 kV and above should not be subjected to routine
cable hipot testing during overhauls, unless there are doubts regarding the cable’s
integrity. In order to conduct a comprehensive and regular hipot test, it is necessary to
disconnect the cables at both ends due to the elevated test voltages involved and the
constraints imposed by the switchgear and related current transformers (CTs).

In order to ascertain warranty accountability and verify the absence of damage during
transportation or installation, it is recommended that newly acquired cables undergo
hipot- or partly discharge-testing both before to and subsequent to their installation.

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The determination of hipot values for cable testing is contingent upon several factors,
including the specific type of insulation material utilized, the thickness of the insulation
layer, and the voltage class associated with the cable. The number of variables is too
extensive to address comprehensively within the scope of this article.

Typically, the post-installation test is conducted at 80% of the factory test value,
whereas routine tests are carried out at 60% of the factory value.

Where the cable manufacturer does not recommend hipot testing, partial discharge
testing should be performed instead. Cable insulation systems are chemically complex
and represent many variations or families within the same generic type—that is, cross-link
poly (CLP) and ethylene propylene rubber (EPR).
The application of high voltage during cable hipot testing has the potential to reduce the
lifespan of certain cable insulation systems due to the induction of molecular alterations,
voids, or a combination of both inside the insulation material.

It is noteworthy to mention that the levels of motor hipot are considerably lower in
comparison to cable hipot values. As a result, they are deemed to be safe for all cable
insulation systems.

Recommended Reading – MV distribution system design based on metal-clad drawout

switchgear

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Sources:

1. Electrical Calculations and Guidelines for Generating Stations and Industrial Plants
by Thomas E. Baker
2. Experience with Stator Insulation Testing & Turn/Phase Insulation Failures in the
Power Generation Industry by Heedong Kim, Taesik Kong (Korea Electric Power
Company) and Sang Bin Lee Korea University, Seoul, Korea

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