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I'd be very careful about surge testing motors in industrial environments. There is specific guidance from IEEE, NEMA and EASA that talks about surge testing being potentially destructive when done on motors in the field. More specifically, motors with unknown insulation conditions. Surge and hi pot testing are geared for shop testing on repaired or new motors. I'd recommend monitoring online impedance imbalance and current imbalance. We've seen many case studies where these two parameters were early indicators of stator faults. I agree that offline, phase to phase resistance and inductance can be great indicators of stator faults. The downside of offline testing is the fact the motor has to be shutdown. We also recommend looking for faults conducive to stator failures. For example, if you have a high restive imbalance on the circuit this can increase heat inside the motor. The increased heat further stresses the insulation system and can lead to bigger insulation or stator failures. If we could have found the small problem, ie. resistance imbalance, then we could have prevented the stator fault.
Stator is a tricky fault zone because faults typically develop so quickly. With a good overall motor testing program you can find the faults that lead to stator issues and get them corrected early.
I was trying to point out that impedance imbalance and current imbalance can act as good indicators for stator issues. It seemed to me that most people in the discussion we're focusing on offline tests and there wasn't much mention of online stator testing.
I always think that these discussions are best if they focus on the technical aspects and remain fairly vendor neutral. That's why I didn't really bring up any vendors in my post. I think these discussions are a great way for people to gather a great deal of knowledge from a large sample of reliability professionals. I hope more threads like this pop up because I'm always interested in new technology and finding ways to better diagnose motor faults.
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