The Insulation Tape: Operation readiness Inspection (ORI) during the Annual Inspections is an event where in the operational efficiency of our Squadrons and workshops is tested. This incident dates back to 1997 during ORI at INAS 333. Hectic flying activity was going on. Two Kv-28 and Two Ka-25 aircrafts were on the task. Various tasks were being given and the HQNA staff were inspecting the operational readiness of the Kamov helicopter squadron. I was the Air Electrical section incharge and, like others, I too was in a spin with various tasks on hand. In between, one of my LEMAs came running to me and told me that one of the Ground power units was not giving any output.My heart skipped a beat as it was the worst thing to happen. The Ground power unit was a Russian manufactured AEMG (Motor Generator set). A 440 volts 3Phase 50 HZ motor driving a generator giving an output of 208V, 3Phase,400 Hz It was a serous issue as a defective GPU will derail the entire flying operations and will bring disrepute to the squadron. It was 12 midnight and the whole squadron was awake undertaking various tasks of ORI.I along with a POELA rushed towards the AEMG. Started it and checked and found there was no output.The laminated circuit diagram was hanging near by. I started tracing the circuit diagram and discovered that one of the control fuse was blown off. I replaced the control fuse and started the AEMG and found there was still no output. The control fuse had again blown off. I now told the POELA to stop the AEMG and checked the insulation of the winding with an inslation Meter(Megger) and found that the insulation was very very low. For Partners unfamiliar with Motor/Generators, every Motor/Generator has windings for carrying the current Supplied/Produced. These windings are nothing but varnish coated wires which are coiled around and insulated from each other and the Machine frame. If the insulation is low it can prevent the generated voltage from reaching the terminals and can also result in a high current flowing through the windings to the body which may result in the windings getting burnt.Low Insulation in winding can be due to many reasons like overheating, overload or moisture inside the windings. In most cases, it is moisture and if blown with warm air the moisture disappears and the insulation improves. So, I told the POELA to bring a blower for blowing warm air on the windings. Meanwhile, I started removing the outer cover of the generator to get access to the windings for blowing warm air. While I was busy opening the cover of the Generator,The Squadron Air Electrical Officer(ALO) sprang up from nowhere in front of me. He saw me opening the cover of the generator and asked me, "KYA HUA"? I told him,"ISKA INSULATION GAYA HAI" ALO casually replied, "ITNA HI HAI KYA. MAI SOCHA JAL GAYA HOGA". I looked at him with surprise. Meanwhile he continued, "Come with me" I asked him, "Kidhar ko sir?" He told,"To my Office" I followed him to his office. He opened his almirah, took out an insulation tape,forced it into my hands and told me, "Jahaan Insulation gaya hai, Yeh Insulation tape chipka dho. Sab teek ho jayega" I couldn't believe my ears. I felt like banging my head on the wall. I really started wondering. Here, I am standing in front of the Squadron Electrical Officer who doesn't know what is meant by Low Insulation of a winding and is offering me an Insulation tape as a solution to improve the winding insulation. I just turned away and went to the AEMG where the POELA was waiting for me with the Blower in hand. We blew the warm air on the windings and successfully improved the insulation and got the AEMG running.It was now giving its rated output. We were observing the performance of the AEMG when the ALO came there again and asked me," Chief saab...Ab kaisa hai. Chal raha hai na"? I nodded my head in the affirmative. He continued," TAPE LAGA DIYA NA?" I did not know what to tell him,"HAAN SIR, LAGA DIYA". He gave a victorious smile and told,"MAINE BOLA THA NA. IT IS VERY SIMPLE". I did not know whether to be angry with him or pity him. Meanwhile, the POELA who was listening to this conversation asked me,"Sir, YEH TAPE KA KYA CHAKKAR HAI". I told him,"Yaar, WOH EK BAHUTH LAMBI KAHAANI HAI. 'ORI' KE BAADH BATATA HOON".
santosh V Santosh Kumar
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Insulation Tape & Motor.... A narration by Santosh

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The Insulation Tape:

Operation readiness Inspection (ORI) during the Annual Inspections is an event where in the operational efficiency of our Squadrons and workshops is tested.

This incident dates back to 1997 during ORI at INAS 333. Hectic flying activity was going on.

Two Kv-28 and Two Ka-25 aircrafts were on the task. Various tasks were being given and the HQNA staff were inspecting the operational readiness of the Kamov helicopter squadron.

I was the Air Electrical section incharge and, like others, I too was in a spin with various tasks on hand.

In between, one of my LEMAs came running to me and told me that one of the Ground power units was not giving any output.My heart skipped a beat as it was the worst thing to happen.

The Ground power unit was a Russian manufactured AEMG (Motor Generator set). A 440 volts 3Phase 50 HZ motor driving a generator giving an output of 208V, 3Phase,400 Hz

It was a serous issue as a defective GPU will derail the entire flying operations and will bring disrepute to the squadron.
It was 12 midnight and the whole squadron was awake undertaking various tasks of ORI.I along with a POELA rushed towards the AEMG. Started it and checked and found there was no output.The laminated circuit diagram was hanging near by.

I started tracing the circuit diagram and discovered that one of the control fuse was blown off.

I replaced the control fuse and started the AEMG and found there was still no output. The control fuse had again blown off.

I now told the POELA to stop the AEMG and checked the insulation of the winding with an inslation Meter(Megger) and found that the insulation was very very low.

For Partners unfamiliar with Motor/Generators, every Motor/Generator has windings for carrying the current Supplied/Produced. These windings are nothing but varnish coated wires which are coiled around and insulated from each other and the Machine frame. If the insulation is low it can prevent the generated voltage from reaching the terminals and can also result in a high current flowing through the windings to the body which may result in the windings getting burnt.Low Insulation in winding can be due to many reasons like overheating, overload or moisture inside the windings. In most cases, it is moisture and if blown with warm air the moisture disappears and the insulation improves.

So, I told the POELA to bring a blower for blowing warm air on the windings. Meanwhile, I started removing the outer cover of the generator to get access to the windings for blowing warm air.

While I was busy opening the cover of the Generator,The Squadron Air Electrical
Officer(ALO) sprang up from nowhere in front of me. He saw me opening the cover of the generator and asked me, "KYA HUA"?

I told him,"ISKA INSULATION GAYA HAI"

ALO casually replied, "ITNA HI HAI KYA. MAI SOCHA JAL GAYA HOGA". I looked at him with surprise.

Meanwhile he continued, "Come with me"

I asked him, "Kidhar ko sir?"

He told,"To my Office"

I followed him to his office. He opened his almirah, took out an insulation tape,forced it into my hands and told me, "Jahaan Insulation gaya hai, Yeh Insulation tape chipka dho. Sab teek ho jayega"

I couldn't believe my ears. I felt like banging my head on the wall.

I really started wondering. Here, I am standing in front of the Squadron Electrical Officer who doesn't know what is meant by Low Insulation of a winding and is offering me an Insulation tape as a solution to improve the winding insulation.

I just turned away and went to the AEMG where the POELA was waiting for me with the Blower in hand. We blew the warm air on the windings and successfully improved the insulation and got the AEMG running.It was now giving its rated output.

We were observing the performance of the AEMG when the ALO came there again and asked me," Chief saab...Ab kaisa hai. Chal raha hai na"?

I nodded my head in the affirmative.

He continued," TAPE LAGA DIYA NA?"

I did not know what to tell him,"HAAN SIR, LAGA DIYA".

He gave a victorious smile and told,"MAINE BOLA THA NA. IT IS VERY SIMPLE".

I did not know whether to be angry with him or pity him.

Meanwhile, the POELA who was listening to this conversation asked me,"Sir, YEH TAPE KA KYA CHAKKAR HAI".

I told him,"Yaar, WOH EK BAHUTH LAMBI KAHAANI HAI. 'ORI' KE BAADH BATATA HOON".

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