Ramakrishna Electrical Winding Works — Routine Test Schedule
Routine test schedule covering every stage from coil manufacturing through stator & rotor assembly to full machine testing. Each test specifies the method, acceptance criteria, sampling frequency and applicable IEC / IEEE / ISO reference standard.
Applicable standards: IEC 60034, IEC 60034-1, IEC 60034-2, IEC 60034-9, IEC 60035, IEEE 43, ISO 1940
| Sr.No | Stage | Test / Inspection | Stage of Test | Test Method | Acceptance Criteria | Frequency / Sampling | Reference |
|---|---|---|---|---|---|---|---|
| 1 | Coil Manufacturing | Visual & Dimensional Check | During manufacture | Measurement / Visual | As per drawing / no visible defect | Each coil | IEC 60034 (visual stage) |
| 2 | Coil Manufacturing | Resistance Measurement | During manufacture | 4-wire Ohmmeter | Within ±2% of design value | Each coil (5% sample verification) | IEC 60034 |
| 3 | Coil Manufacturing | Insulation Resistance (IR) | After VPI / impregnation | Megger (500V or 1000V) | ≥100 MΩ @ 40°C | Each coil | IEC 60034-1, IEEE 43 |
| 4 | Coil Manufacturing | AC High Voltage Test | After slot placing / after wedging / completed winding | Dielectric withstand (2U + 1 kV, 1 min) | No breakdown or partial discharge >5 pC | Each coil | IEC 60034 |
| 5 | Coil Manufacturing | Surge Comparison Test | Pre- and Post-impregnation / after slot placing | Surge tester (waveform comparison) | Waveforms identical, no shorted turns | Each coil | IEC 60035 |
| 6 | Coil Manufacturing | Tan δ / Capacitance | After impregnation | Capacitance bridge (0.2U–1.0U stepwise) | Smooth increasing trend, no sudden deviation | Each coil | IEC 60034 |
| 7 | Stator & Rotor Assembly | Dimensional Check (Air Gap, Core Fit) | Assembly stage | Feeler gauge / Dial gauge | As per drawing ± tolerance | Each machine | IEC 60034 mechanical checks |
| 8 | Stator & Rotor Assembly | Winding Resistance | Post-assembly | Bridge method | Phase unbalance ≤1% | Each machine | IEC 60034 |
| 9 | Full Machine Testing | IR & PI (Polarization Index) | Before run test | Megger (1kV/5kV) | IR ≥100 MΩ, PI ≥2 | Each machine | IEEE 43 |
| 10 | Full Machine Testing | HV Test | After winding connection | 2U + 1 kV, 1 min | No flashover/breakdown | Each machine | IEC 60034 |
| 11 | Full Machine Testing | No-load & Load Test | Final test | Performance test bench | Efficiency & PF ≥ nameplate | Each coil | IEC 60034-2 |
| 12* | Full Machine Testing | Vibration Test | Final test | Vibration meter (RMS) | ≤2.8 mm/s (ISO 1940) | Each machine | ISO 1940 |
| 13* | Full Machine Testing | Noise Test | Final test | Sound level meter | ≤85 dB(A) | Each machine | IEC 60034-9 |
Note: * These tests are conducted based on the availability of complete machine.
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