PROCEDURE OF CORE HOT SPOT REPAIR

The procedure describes the steps to repair Core Hot Spots of large motors resulting from
rubbing of stator & rotor
Introduction:
Core of Induction motors are built of laminar magnetic steel sheets stacked together with very thin
layer of insulation varnish in between. This type of construction is done to minimize core loss and
inductance. This interlayer insulation is susceptible to damage/ deterioration due to aging or
generation of frictional heat in case of fouling of stator and rotor. While the former is a natural
process and occurs almost homogeneously in the core and nothing much can be done against it but
the later which is a localized defect can be repaired to a great extent.
The benefit of carrying out such repair is mainly containing the heat generation in core that may
lead to damage of nearby conductor insulation. Thus, it not only reduces the core loss but also
increase life expectancy of the motor without incurring cost and a prolong repair outage.
If on dismantling of a motor it appears that the stator and rotor core has rubbed one another a
Hot Spot Test is recommended to assess the degree of damage and the locations thereof. Then the
decision to conduct such repair is to be taken.
Before the checking and repair begin the identified areas are to be suitably marked.
Hot Spot Test

MCB

Fig 1

415 V, 50 Hz, AC

After dismantling the motor & withdrawing rotor from the stator, insulated 2.5 mm2 insulated copper
wire is to be wound around the stator frame (vide fig 1). Sufficient number of turns is to be wound so
that a 415 volt 50 hz AC supply can be impressed across it. This will depend on the size & speed of
motor or in other words the sectional area of core. (This can be done by simple trial & error,
wounding a large number of turns initially, putting the supply on and checking the

current with clip on ammeter and then reducing/ increasing the turn further to fix the current to the
range of 28-30 Amps. For example, in a typical 800 KW 1500 RPM 6 KV motor 24 turns of. PVC
insulated 7/20 copper wire was found be appropriate.).
The AC supply should preferably be routed through a 30 Amp MCB for protection & isolation.
Before the supply is switched on the motor body must be properly earthed and the setup is not to
face any forced cooling arrangement. Temperatures of different areas are to be noted by a
reliable thermometer. (Thermocouple or infrared thermometer is good for the purpose.)
Note the temperatures at different regions specially the rubbed zone that has been marked earlier.
After about 10-15 minutes an overall rise in temperature of the core will be observed.
Temperatures in the affected zones will be higher than remaining zone by at least 8-10 deg C.
Mark these zones because these are the areas where repair activity is to be done. (It is advisable that
if the damaged area thus identified is more than 10% of total area, then restacking of total
core will be a better option).
After Hot Spot Test the setup can be removed or retained. The set-up will again be required to
check the effectiveness of repair.
Repair Activity
The following materials and tools are to be made available for the said job
1. Small pillows (6"x0.5") made with good quality cotton packed in cotton cloth. (Sufficient
number is to be made ready as they get consumed quite fast)
2. A block of dimension 6"x0.5" made from SS-316, which would serve as electrode.
3. 20% phosphoric acid
4. A 24V variable DC power supply that can be regulated to supply current up to30 Amps
(can be easily arranged by connecting variac , bridge rectifier & few instruments
correctly)
5. Loctite 290 or equivalent
6. Varnish & lamp heating arrangement.
7. Magnifying glass, Angle grinder, Sand stone & Emery paper
8. Protective hand gloves & nose mask (phosphoric acid has very adverse effect on skin &
bones and contact is to be avoided)
Procedure of Stator core repair by electrochemical or etching process:
1. Damaged areas of Stator core is to be cleaned with angle grinder. (Alternatively, cleaning
with sand stone & emery paper can be done which is felt to be better option by some
others.)
2. The Negative polarity of 24V DC power supply is to be connected to the electrode and
Positive supply to the stator core.
3. Pillows are to be soaked in 20% phosphoric acid and wringed so that they are just wet.
4. Wetted pillow is to be placed on the damaged part of stator tooth surface with the
electrode sitting & pressing on top of it.

5. DC supply is to be switched on and initial current set to the order of 20-25 Amps. The
current will gradually start to reduce with time.
6. DC supply is to be switched off at around 10 Amps.
7. A fresh wetted pillow is again to be applied on the same spot and the process is to be
repeated on the same slot for 3-4 times.
8. The stator tooth to be cleaned inspected with magnifying glass to detect any shorted
lamination and hot-spot test was done.
9. Once the process has been carried out all around, the hot spot test is to be performed
again. Steps 2 through 9 may need to be repeated few more times, till tooth temperature
comes down to ambient + 5 deg C.
10. Loctite 290 is to be applied on the damaged stator stampings and left for 24 hrs.
11. Motor stator to be varnished and dried.
If required HV test (at
about 10 days.

9KV DC) can be done on stator winding. The etching process can take

Since rubbing of stator & rotor is the root cause of this failure, before reassembly of motor the
following are to be ensured.
Trueness of rotor shaft
Proper balance of rotor mass
Bearing Housing and shaft journal are correctly machined.
All bearings are to be replaced with new ones.
Damaged wedges in stator slot are also to be re paired & heat-varnish applied.
Why Loctite 290 was used ?
The varnish surrounding the parts where the stamping has rubbed would have burnt off the
stamping surface. It is important to replace the varnish reinforcement. Loctite 290 was used for the
purpose because it would penetrate any gaps of less than 0.002 in. For a distance of at least 4 inch
against gravity, and would harden against and bond bare metal surface together.
Hazards & Precautions:
Phosphoric acid attacks calcium. It can attack bones even if it comes in contact with skin
for some time. Hence rubber gloves are to be used.
As Hydrogen is liberated during the etching process effective ventilation is required.
Naked flames are strictly barred from the test location.
Quartz wrist-watches on can malfunction if inserted inside the core during temperature
measurement of hot-spot test. It is advised to keep such watches in the pocket during the
test.

For more info: contact EMD, BBGS