Power Generation - Handout

Turbo / Hydro Generator Stator - Rotor Winding Construction
March – 2008 edited October 2010

Handbook
Sis Cahya Bhuwana
Inspections / Testing / Analyzing
Power Generation
(Turbo and Hydro Generator)
/ Repair / Inspections / Testing / Analyzing Handbook
2008
[Generator rotor thermal sensitivity is a phenomenon found on the

generator rotor causing change in vibration as the field The most
likely problem with operation in the presence of shorted field
windings is excessive vibration.
This Turbo Generator Stator-Rotor Repair / Inspections / Testing /
Analyzing Hand Book is basically used engineer as guidance to
selection of insulation material for rewind or reinsulation of rotor
turbo generator, with gas cooled or air cooled systems.
This Handbook is compiled by Siswanto is based on many
literatures and site works projects for services and inspections of
turbine generators. This handbook is an effort to provide as much
information to our customers as possible in order to select the best
material for the optimal performance of the generator. To get in
complete material information you can found in our Material
Specification Based On NEMA LI-1 Standard, March 2008.
[email protected], [email protected]
Blog: www.sispowergeneration.blogspot.com
CR4 Forum : http://cr4.globalspec.com/member?u=14927
Mobile phone : ++62 81 311 422270. Jakarta. INDONESIA
Compiled by : Siswanto , March 2008,
Page 1 of 142
Telp : 081311422270, Email: [email protected]
2008
Preface
This Turbo / Hydro Generator Stator - Rotor Repair / Inspection / Testing /
Analyzing Hand Book is basically used engineer as guidance to selection of
insulation material specification for rewind or reinsulation of Stator - Rotor Turbo /
Hydro generator, with gas cooled or air cooled systems, Inspections and Testing.
This Handbook is compiled by Siswanto based on many literatures and our site
works projects experiences for services and inspections of turbine generators.
This handbook is an effort to provide as much information to our customers as
possible in order to select the best material for the optimal performance of the
generator. To got in complete material information you can found in our Material Specification Based On
NEMA LI-1 Standard Handbook, March 2008.
In practice during to performed our projects in Indonesia ( Rewinding / Reinsulation / Inspections /
Testing / Analyzing of Power generation) is require complex equipments and instruments, to provide that
all equipments and instruments we are collaborate with the independent companies ( Non Manufacture
Company) they support us by their Equipments / Instruments and Engineers.
Evaluation of the actual condition of a generator is a challenging task. Inspection has several limitation:
necessary to disassemble components, many areas cannot be seen even with the best tools including
robots, results are qualitative and highly operator dependent, time consuming. Each of the many tests
also has one or more of several limitations: cannot find local discrete weak areas without risk of insulation
breakdown, gives averaging results only, insensitive to vital deterioration mechanisms, requires
specialized equipment, personnel hazard.
However, the two approaches to generator assessment – inspection and test – are quite complimentary.
The combination of a good testing program and thorough inspection by a skilled and trained individual
can give a good assessment of almost all common forms of generator deterioration. On generators that
are important to system reliability, it is important that both test and inspection be performed, and that
neither be neglected nor superficially done.
In this paper inspection equipment and procedures will be discussed rather comprehensively but in
relatively non-technical terms. The paper will be heavily illustrated to show actual machine conditions on
most all of the known deterioration mechanisms on generators. This information should help those
responsible for inspecting generators to better understand the strengths and weaknesses of generator
inspection procedures, and provide operators of generators a more reliable inspection of the generator. It
should also assist owners of generators in implementing better maintenance practices, and thus reduce
maintenance costs and extend reliable life of the generator.

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TABLE OF CONTENTS
TABLE OF CONTENTS PAGES
Cover 1
Preface 2
Table of content 3-7
I STATOR 8 – 26
A High Voltage Insulation system and construction 8 – 20
A.1 Winding in general 8–9
A.2 Winding construction 9 – 20
A.2.1 Coil material 11 – 12
A.2.2 Coil winding construction step by step manufacturing process 12 – 16
1. Copper strip (wire strand) 12 – 12
2. Strand / turn insulation 12 – 12
3. Loop winding 12 – 13
4. Roebbeling 13 – 15
5. Coil spreading 16 – 16
6. Coil shape check 16 – 16
7. Ground wall insulation 16 – 16
a. Insulation tapping system 16 – 18
- Wrapping by discontinuous method 16 – 16
- Wrapping by continuous method 17 – 17
8. Corona protection 18 - 18
9. Coil overhang 18 – 18
10. Coil pressing 19 – 19
11. Coil lead 19 – 19
12. Individual coil testing 19 – 19
13. Post curing 20 – 20
B Summary of HV coil test specification 20 – 23

B.1 Special Test 24 – 25
1 Voltage Endurance Test 24 – 24
2 Thermal Cycling 25 – 25
B.2 Coil Installation 25 – 26

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II ROTOR 27 – 43
A Rotor turbo Generator 27 – 40
A.1 Rotor Winding Parts 27 – 29
A.2 Coil Winding Configuration and Material 29 – 39
B Salient Poles 40 – 43
III INSPECTION AND TESTING 43 – 121

A Inspection Quality Plan 44 – 47
B Testing Basic Concept 47 – 51
B.1 Stator Insulation aging mechanism 47 – 48
B.2 Basic Inspection Level 49 - 49
B.3 Life Time Analysis 50 - 51
C Testing in basic concept Explanation 51 - 53
C.1 Monitoring Level 1 (generator on line ) 51 – 51
C.2 Monitoring Level 2 51 – 52
D Stator Testing 54 - 72
D.1 Insulation Resistance and Polarization Index (PI) 54 – 55
D.2 Winding Resistance 56 – 56
D.3 Hi Pot Test 56 – 59
D.4 ELCID Test 59 – 60
D.5 Insulation Dissipation Power Factor and Tip Up 61 – 62
D.6 Partial Discharge 62 – 69
D.7 Natural Frequency 70 – 70
D.8 Contact Coefficient ( Coupling Resistance ) 70 – 70
D.9 PDCA (Polarisation Depolarisation Current Analysis) 71 – 72
E Rotor Testing 72 – 81
E.1 IR / PI / PDC 72 – 72
E.2 Turn to Turn Short Test 72 – 72
1. RSO (Recurrent Surge Oscillation) 73 – 73
2. AC Impedance 73 – 73
3. On Line Rotor Inspection 74 – 81

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a. Introduction 74 – 74
b. Online Rotor Short Detection 75 – 79
c. The Causes of Shorted Turn 79 – 81
F VISUAL INSPECTION 82 – 118
F.1 STATOR 82 – 99
1. Frame Stator Extension 83 – 83
2. HV Winding & Flexible Bus Connection 83 – 83
3. End Winding, Connection Rings and Support 84 – 84
4. Blocking Condition and Ties 84 – 89
5. Surge Rings Insulation Condition 85 – 85
6. Surge Rings Support Assembly 85 – 85
7. Core Compression Nuts and Bolts 86 – 86
8. Out Going Cable Support 86 – 86
9. Insulation Condition 86 – 87
10. Tape Separation 87 – 87
11. Insulation Galling 87 – 88
12. Insulation Bulging 88 – 88
13. End Winding Blocking Coil and Ties 88 – 88
14. Corona Activity 89 – 89
15. RTD and TC 89 – 89
16. Fan Baffle Support Stud 90 – 90
17. Endwinding Support Hardware 90 – 90
18. Circumferential Bus Insulation 90 – 90
19. Bar Bottomed in Slot 90 – 90
20. Core Inspection 91 – 91
21. Lamination Bent or Broken 91 – 92
22. Wedge Mapping 92 – 98
a. Wedge Function 92 – 93
b. Acceptance criteria 93 – 93
c. New Stator wedge 94 – 95
d. Stator wedge Design 95 – 95

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e. Material 96 – 98
23. Core Dampen Bars 98 – 99
F.2 ROTOR INSPECTION 100 - 118
F.2.1 ROTOR TURBO GENERATOR 100 - 110
1. Rotor Cleanliness 100 – 100
2. Rotor Wedge Inspection 100 – 101
3. Retaining Rings Visual Appearance 101 – 102
4. End Winding Blocking 102 – 103
5. Retaining Ring Removal Inspections 104 – 106
6. Rotor Forging NDT Inspection 106 – 107
7. Degaussing 107 – 110
8. Schematic Rotor Area Prone to Damage 111 – 115
F.2.2 ROTOR HYDRO GENERATOR / SALIENT POLES 116 – 118
1. Rotor Cleanliness 116 – 116
2. V Block Rotor inspection 116 – 116
3. Insulation Between Turn 117 – 117
4. Starting Bars (Damper Bars Winding ) 117 – 118
5. Bull Rings Segment and Brazing to Starting Bars 118 – 118
G GENERATOR PROJECT PROFILE 119 – 121
IV ROTOR THERMAL SENSITIVITY PHENOMENA‟S 122 - 128

A Theory 122 – 122
B Testing for Thermal Sensitivity 123 – 124
C Cause Thermal Sensitivity 124 – 128
1 Shorted Turn 125 – 125
2 Blocked Ventilation 125 – 125
3 Insulation Variation 126 – 126
4 Wedge Fix 126 – 126
5 Distance Block Fitting 127 – 127
6 Retaining Ring / Centering Rings Assy 127 – 127
7 Tight Slots 128 – 128

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8 Heat Sensitivity Rotor Forging 128 – 128

D PROJECT EXPERIENCES 129 – 139
1 Background 129 – 129
2 Loading Data before Repair 129 – 129
3 Rotor Removal 130 – 131
4 Thermal Sensitivity Test After Repair 131 – 139
a. Dynamic Test 131 – 132
b. Static Test 132 – 134
c. Loading Data and Thermal Vector 134 – 138
5 Start up procedure 139 – 139
6 Annex Data Test Thermal Sensitivity 139 – 139
E REFERENCES 140 - 142

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I. STATOR
A. High Voltage Insulation Systems and Constructions
A.1. Winding in general
This paper will focused for the Power Generation High Voltage, in generally has applied for Power Plant,
(Steam / Gas Turbine Generator or Hydro Generator).
Stator Winding for Hydro Generator is typical with Steam or Gas Turbine Generator, but Rotor Hydro
Generator, basically is different design, this paper will discussed both generators (Hydro and Turbine
Generator)
Insulation winding on the rotating electrical machines including generator are classified by thermal class.
Following table is thermal class on for the winding insulations,
1. Class A: Permissible Maximum temperature winding = 1050 C

2. Class E: Permissible Maximum temperature winding = 1200 C
3. Class B: Permissible Maximum temperature winding = 1300C
4. Class C: Permissible Maximum temperature winding ≥ 2000 C
5. Class F: Permissible Maximum temperature winding = 1550 C
6. Class H: Permissible Maximum temperature winding = 1800 C
The stator winding is made up of insulated copper conductor bars, following are copper conductors are
normally used for electrical machine winding.
Table. A.1 __Enamel Base Wire application
Type Enamel Base Class Application

Duroflex Modified polyvinyl acetal E Oil immersed Transformer
Soldex 155 Modified polyurethane F Solder able
Thermex 180 Modified polyesterimede H Transf. Motors
Thermex 220 Modified polyamideimide C Nuclear application
High thermal stress

Thermex 240 Polymide C
winding
Ref: Von Roll Issola

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Table. A.2__ Wire paper insulation application
Type Description Class Application
Single Dacron Polyester fused to the conductor and F Salient pole Winding, Magnet coil,
Glass varnished DC field, armature
Double Dacron Polyester fused to the conductor and F Salient pole Winding, Magnet coil,
Glass varnished DC field, armature
Single Fiber Glass Varnished Fiber glass filament F DC field winding
Double Fiber Glass Varnished Fiber glass filament F DC field winding
NOMEX ® (Aramid 0.005” (0.127mm) bonded to H Transformer, Magnet coil

paper) conductor
Nomex paper single 0.013” (.33mm) bonded to conductor H Dry type Transformer, Magnet
dacron glass coil, Armature
Kapton® (Polymide 0.006” (0.15mm) bonded to conductor C Traction motor (stator, rotor)
Film)
Polyester film 0.013” (0.33mm) bonded to conductor B For 3.3 & 6.6 kV winding
Single dacron
Enamel (HPAM) (0.1 – 0.15)mm Heavy Polyester H AC coil 3.3 / 6.6 kV, Field coil
Amide Imede coted to conductor
Dacron glass over (0.25-0.3mm)Sngle / (0.3-0.35mm) H AC Coil 3.3 / 6.6 kV, Rotor
HPAM double Dacron over HPAM winding, Field coil
Kraft paper Kraft paper bonded to conductor B Oil immersed transformer
MICA .35mm Mica paper and Polyester Film F A.C Coil 6.6 / 11kV
bonded to conductor
® DUPONT Ref: Westral Insulated Products PTY LTD

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A.2. Winding Constructions

The insulated copper conductor bars that are use for winding are distributed around the inside diameter
of the stator core, commonly called the stator bore, in equally spaced slots in the core to ensure
symmetrical flux linkage with the field produced by the rotor. Each slot contains two conductor bars, one
on top of the other (see figure 2-1.Stator winding construction in the slot).
These are generally referred to as top and bottom bars. Top bars are the ones nearest the slot opening
(just under the wedge) and the bottom bars are the ones at the slot bottom. The core area between slots
is generally called a core tooth.
Fig.A.1 Stator winding construction in the slot.
Wedge Packing
Stator Core
Stator Core Separator

(Cooling Duct)
Stator Dovetail Tooth
Top Filler
Side Ripple Radial Spring

Packing
Semiconductive Bar Armor
Groundwall Insulation
Slot Separator
Transposition Filler
Solid Copper Strand

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Fig. A-2. Stator Winding Insulation Construction
A.2.1. Coil Material Properties in History

Fig. A.3 HV Coils section
Stator Winding basically are designed based on
to thermal class and voltage rating of the
machine. Higher voltage rating need much layer
on the winding insulations, insulation
construction see fig 2-2 above.
For old machines (build within year 1930s) the

manufacture began utilizing asphalt as the
bonding agent for the insulation of large
synchronous machines. A asphalt was used to
bind mica flakes ( called asphalt micafolium) to
form the wall insulation or was used to bond the
mica flakes to a tape (called asphalt mica tape),
for the modern machine (1950s) the manufacture
was gradually replaced by thermo plastic insulation (called thermosetting insulation).
Asphalt based insulation systems are prone to develop a number of problems that are very specific to the
thermal class of insulation. A major disadvantage of the asphalt-based insulation is its poor thermal

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resilience. When exposed to high temperatures, the asphalt develops a sharp drop in viscosity and thus
tends to migrate along to the coil to areas of less pressure, its can allowed flow out of the coil.
Thermosetting is better voltage breakdown and thermo class than asphalt-based insulation, Both
insulation systems were tapping on the copper bar conductor as many layers, number of layers of tape
depended on the tape thickness and rated voltage of the machine.
Better quality of material will allow increased voltage stresses in the ground wall, and its will resulting
in thinner insulation‟s with better heat dissipation, providing more space for increased copper
content.
A.2.2. Coil winding construction step-by step manufacturing process. :
1. Copper strip (wire strand)

The conductivity copper of winding at least minimum 99.9 % and no surface defect
2. Strand / Turn insulation

Turn insulation normally consisting of mica tape (sometimes enamel depending on space
availability) with a special adhesive coating that melts at high temperature to bond and
consolidate the insulated strands. The consolidation is carried out in the special presses and
therefore ensure a correctly dimensioned wire pack, which does not move during manufacture
and conductor do not oscillate during operation.
Fig.A-4. Turn insulation
Additional stranded covering by Mica Tape on to Enamel Conductor or Bare Conductor for strand / turn
insulation normally for winding with rated voltage ≥ 6 kV
For high voltage machine (11 kV and above) dedicated turn tape is normally applied over the strand
insulation consisting of resin rich mica tapes. Turn tape is then press bonded in special presses to
exclude all voids and ensure a correctly dimensioned wire pack.
3. Loop winding
Placed the copper real tensioners on each reel strands per turn, Loop can be wound with pin centers
Long leads supplied for coil connections to make winding connection easier and quicker for winder and
then dedicated turn tape insulation if required.

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Fig A-5. Looping winding
4. Roebeling
Fig A-6 Roebel forming winding (manual machine)
The currents normally flowing in large turbo generators can be in the order of thousands of amperes. Due
to the very high currents, the conductor bars in a turbo generator have a large cross-sectional area. In
addition they are usually one single turn per bar, as opposed to motors or small generators that have
multiple turn bars or coils. These stator or conductor bars are also very rigid and do not
bend unless significant force is exerted on them. The high current capacities of copper in the stator bars
generate significant heat. The losses due to the flowing currents are called I 2R losses in the winding.
Controlling the losses in the stator winding requires careful design consideration because of the variance
in magnetic field from the stator bore toward the slot bottom. The magnetic field tends to be more intense
toward the top of the slot, and therefore the top bars generally produce more heat than the bottom bars.
Within the bars themselves, there are also “eddy” currents flowing in each bar caused by the localized
leakage magnetic field. To reduce the effect of the eddy currents within each individual stator bar, the
conductors are made up of numerous copper “strands” . This is similar to the reasoning behind the stator
core being made up of laminations rather than a solid mass of steel. However, although the strands are
insulated from one another in the bar, they are eventually connected at each end of the stator bar.

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Therefore additional circulating current could flow from top to bottom strands in a single bar. This is due
to the difference in the magnetic field from the top to bottom of the slot. To reduce the effect of the
circulating currents, the strands are “Roebel Transposed” in each bar.
Roebel transposition of the copper strands refers to the re-positioning of each strand in the stator bar
stack such that, it occupies each position in the stack at least once over the full length of the stator bar.
There are 360 and 540 degree Roebel transpositions found by and large. A 360 degree transposition
means that each strand occupies each position once over the length of the bar, and a 540 degree
transposition means that each strand occupies each position one and a half times. The 360 transposition
is generally done in the slot only and the 540 transposition is done out to the very ends of the stator bars,
and in the curved end-winding portion as well.
Fig. A-7 . Robotic Roebeling machine
Fig. A-8. Roebel Winding

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Stator conductor bar cross sections. (a)

Indirectly cooled stator conductor bar; (b)
directly gas-cooled stator conductor bar; (c)
directly water–cooled stator conductor bar.
(Courtesy of General
Electric).
a b c
Fig. A.9. Roebbeling coil form

Roebel transposition map. (Courtesy of Alstom Power Inc.).

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5. Coil Spreading
Fig A-10: Coil Spreading
6. Coil Shape Check

Coils designed to meet set clearance and design criteria in relation to the voltage. Coil shape checks
after spreading operation. Coil shape checks after pressing operation. Marking of Corona protection and
armouring tapes in Mock Stator to ensure accuracy
Fig A-11 : Coil shape ceck in the “Mock Stator”
7. Ground wall insulation

Consist of multiple layer of ½ lapped resin rich mica tape bonded with epoxy resins. The wrapping
method can be applied by discontinued or continued by machine tapping or hand tapping.
a insulation tapping systems
a.1 Wrapping by discontinuous method
The manufacturing of coils using mica tape can be achieved by the discontinuous method ways: The
main insulation is applied to the un-stretched coil. Both slot section of the coil are wrapped with full width
mica tape and then pressed. The edge of insulation are cleaned , Mica –paper tape are then used to
insulated the end winding using special tape (example FEINMICAGLAS or CALMICA-FLEX – ISOVOLTA
Product) flexible end winding tapes. These tapes should join up flush with the end of main insulation

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a.2. Wrapping by continuous method
By using Mica tape ( example by CALMICAGLAS®- Isovalta product) in tape form the straight slot
section and overhang can be taped in a continuous taped sufficient distance around the first slot section
bend, . The conductor stack is taped half-overlapped is then pressed and the end winding cured in oven
if necessary with a varnish. During tapping process uniformly tape thickness and tension around in the
coil section must be maintained to achieve desired void free structure of correct density
Fig A-12 : Wall insulation tapping by tapping machine
The layer number of insulation tape can be calculated with based on to tape thickness after pressed.
Following is example to calculation of layer number for insulation winding (data taken form Insulation
material: CALMICA®, Product: ISOVOLTA
Wrapping of coils and bars with CALMICA® tape can be wrapped with tapping machine and or by hand.
The nominal thickness of CALMICA® is 0.16 mm as supplied and approximately 0.125 mm when
pressed.
The no. of insulation layer materials required can be calculated by referring to the technical data showing
values after pressing.
Table A.3___Table tapping thickness
Un KV ≤4 6 10 12
Thickness mm 1.0 1.5 2.5 2.8
Example:
Un = 12 kV, the insulation thickness would be 2.8 mm.
Utilize the insulation CALMICA 0.16 mm with approximately 0.125 mm when pressed,
The no of layer required : 2.8 / 0.125 = 22.4 layer app. 23 layers must be applied on to coils winding

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8. Corona protection
Corona protection are comprised of conductive tape, which is moulded during finale pressing cycle and
becomes an integral part of the coil side, integrally moulded corona tape systems limits of surface
resistivity are between 0.2 and 20 kΩ / square. On coils 11 kV and above normally applied by silicone
carbide grading paint with voltage dependent resistivity (VDR) from the slot end through the first bend.
Wall insulation Corona Protection Silicone Carbide Grading Paint
Fig : A-13. Anti corona protection
9. Coil overhang
Coil overhang, normally are consist of multiple layer of ½ lapped fully cured mica tape and finished with a
resin rich sealing tape, which produces a water tight and smooth protective layer. A special high
molecular weight epoxy resin is applied between all layer of mica tape and is used to bond the basic
insulation materials together and fill many small voids. The resin is not cured during coil manufacturing
and therefore keeps flexibility in the coil overhang making the coil easier and quicker to install. The
complete winding requires final oven cure.
Fig. A. 14 Wall insulation tapping

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10. COIL PRESSING

Pressing and dimension check for each coil is should performed to ensure the uniformly dimension to fit
in the slot .
Fig. A-15. Coil pressing and dimension check
Coil in molding press Dimension on slot cell
11. Coil Lead

Each lead normally is individually tapped with multiple layers of mica tape finished with resin rich sealing
tape. A silicon rubber compound is used for sealing of the leads.
12. INDIVIDUAL COIL TESTING

Every coil strand tested to BS EN 50209.
Every coil Surge comparison tested to IEEE Std. 522.
Cross section of coils Tan Delta tested to BS EN 50209. Minimum of 10% coil sides or as agreed with
Customer.
Voltage endurance testing can be performed where agreed (OPTION) .
Fig A.16. Test set on coil
Hi Pot Test on each coil Tan Delta Test on each coil
Detail test specification see to next chapter bellow.

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13. POST CURING
Steel mock stators for large post curing (large hydro), guaranteed
correct shape.
Fig.A-17 Post Curing coils on the Mock
B.. SUMMARY OF HV- COIL TEST SPECIFICATION

Coil Test
Test references:
- IEEE standard , BS, EN, ESI
Strand – strand test at 240 volts AC

All coils with more than 1 strand in parallel per turn are strand – strand tested. This test the integrity of
the strand insulation between adjacent strands of the same turn. Even though the voltage potential is
very small between strands, shorted strands can cause localized heating due to an increase in eddy
currents in shorted strands.This heating can progress to damage to the strand and turn insulation and
can lead to turn-turn failures.
Turn-turn testing
All coils with more than 1 turn are turn to turn tested. This test the integrity of the insulation between
adjacent turn in the coil. Coils are tested with 0.2 µs rise time to the equivalent 1.79 x line voltage with a
minimum of 5 pulses.
The test equipment such as Surge comparison tester
High Potential Test of ground wall insulation

All coils are tested result are measured in leakage current (µA) result of the testing are dependent on
temperature and humidity , as in most cases the coil is in an uncured state. Coil are tested for one minute
to the equivalent of `120% ( 2 x Line voltage + 1 kV ac ).
Coil are tested with DC with a multiplication factor of 1.73. steel guards the length of the slot portion are
fitted to the coils to simulate the insertion of the coil into the stator slot.
Tangent Delta Testing

Tan Delta Testing measures the uniformity of manufacture by measuring the dielectric loss angle at 0.2,
0.4, 0.6, 0.8, 1.0 increments of the Line voltage of the coil
Prototype testing
Some of tender requirements require extra prototype testing to be carried out
Test can include:
- Impulse testing of turn insulation for simulation of lightning strike
- Destruction testing of turn insulation
- Impulse or Power frequency testing of Main insulation
- Destruction testing of main insulation
- Accelerated Voltage endurance testing with or without thermal cycling
- Tan Delta testing at ambient temperature before and after a 900C temperature rise

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Test Based on IEEE and BS – EN

Turn to Turn Testing
IEEE 522: 2004 BS EN 60034-15: 1996
Standard Test Voltage: Standard Test Voltage for coils 3 kV to 15 kV:
2.86 VL at 0.1µs min 5 pulses

2.98 VL at 0.2µs min 5 pulses
Reduced with agreement:
1.63 VL at 0.2µs min 5 pulses (4VL + 5kV) x 0.65 at 0.2 µs, min 5 pulses
- Resin Rich tested at 40% to 60% Voltage :
- VPI 60% to 80% voltage
Max : [(2xVL) + 1kV] x 1.7
Min Voltage : 350 V per turn
Normally coils will be tested at 60% voltage with 0.2µs rise time to the equivalent of 1.79 x Line voltage
with a minimum of 5 pulses.
High Potential Test of Ground Wall Insulation
IEEE 95: 2002 ( > 5kV ) BS EN 60034-1: 2000
2 x VL + 1KV ac for 1 minute 2 x VL + 1 kV ac for 1 minute

Factor 1.2 or 1.7 maybe applied (or equivalent if rated 6kV or greater)
Insulation Resistance
IEEE 43 - 2000
VOLTAGE RATING (VOLT) TEST VOLTAGE (VOLT)
1000 - 2500 500 – 1000

2501 - 5000 1000 – 2500
5001 – 12 000 2500 - 5000
 12 000 5000 – 10 000
Inter Strand Test
IEEE BS EN 50209 : 1999
Test Voltage 110 V ac

Between conductor lamination insulation
Normally strand coils to be tested at 240 Vac

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Insulation Power Factor Tangent Delta Testing
IEEE 286: 2000 ( tip-up)

BS EN 50209 : 1999
Standard for coil 6kV or above Standard for coils 5kV to 24kV
(above 11 kV testing to be agreed)
Sample size to be adequate for statistical Sample Testing :

sampling analysis <5MW, 10% of coils, min 10
5 to 50MW, min 30 coils+10% of coils.
>50 MW, 2&4 poles, All
>50MW, (6 poles or more) , min 30 coils +10% of
coils
Capacitance and Tan Delta change per
increment of 0.2VL or greater step up to
1.2VL Testing Loss Tangent ( ≤ 11 kV )
Per unit Tip-Up measured Tan Delta 0.2 VL = max 0.03
(TanDelta1.2VL  TanDelta 0.2VL ) TanDelta 0.6VL  TanDelta 0,2VL

 =
TanDelta1.2VL 2
0.025 for 95% and 0.03 for 5%
Cell capacitance within 10% of calculated
value Maximum Tan Delta change per increment of 0.2VL
steps
Used for comparison testing of coils = 0.005 for 95% and 0.006 for 5%
Prototype type test as per customer requirement
Impulse Testing of Turn Insulation (Simulation of Lightning Strike)
IEEE Std 522: 2004 BS EN 60034-15 : 1996
Impulse voltage between coil terminals and Impulse voltage between 2 terminals of same
earth (shield simulating core). coil.
2
Impulse voltage of 5 x (VL [ ] with front
3 Impulse voltage of (4 x VL + 5kV) x 0.65 with
time of 0.2 µs, repeated 5 times. front time of 0.2 µs, repeated 5 times
Insulation must not fail Insulation must not fail
This is a destructive test IEC requires two fully cured coils.

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Impulse Testing of Main Insulation
IEEE Std 522 : 2004 BS EN 60034-15 : 1996

Impulse testing between coil terminals and Impulse voltage between coil terminals and
earth (shields simulating core). earth (shields simulating core).
2 Impulse voltage of (4 x VL + 5kV) x 0.65 with

Impulse voltage of 5 x ( VL ] with front front time of 1.2 µs, repeated 5 times
3
time of 1.2 µs. repeated 5 times
Insulation must not fail Insulation must not fail
Destruction Testing of Turn Insulation
IEEE BS EN 50209 : 1999
Tested with opened coil

Withstand 0.3 x VL ac applied to adjacent
turn for 1 minute.
Immediately rise at 0.5 kV /s until breakdown
occurs
Voltage Endurance Testing for Formed Coils
BS EN ( not
IEEE 1043 : 1996
available)
Coils to be hi-pot test at 110% of endurance voltage for 1 minute and Tan
Delta tested before endurance test.
Test conducted at air.
All conductors connected to constant stable voltage with protection, coil test
sample to be 250 cm or half bar length .
Heater elements 75% length of heater plates. Heater plates to be connected
to earth and clamped to have < 0.2 mm gap with the coil.
Test temperature range 1200C to 2400C. Temperature measured every 15
minutes with a maximum rise of 20C
Supply voltage measured at every 0.1 hr. the timer is stopped if no voltage.
Test completed when retest also fails.
Expected life if insulation statistically calculated.
This test a destructive test on five fully cured coils. This test can run for months.

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B.1. Special Test

Endurance and Thermo cycling
Laboratory Diagnostic Tests of Stator Winding Insulation
Downtime at generating stations and industrial plants caused by failure of stator insulation can be
expensive. To minimize the risks of machine insulation failure, insulation must withstand the stresses in
high voltage generators and motors. If you purchase new stator windings or have spare stator
windings, how do you know that your stator windings meet the design specification and perform as
expected? How do you know the winding manufacturing quality that is relevant to machine operation
reliability and machine service lifetime?
1. Voltage Endurance Tests
voltage endurance tests on stator bars or coils in accordance with IEEE Standard1043-1996 and IEEE
Standard 1553-2002.
A voltage endurance test is an accelerated insulation-aging test. The test is performed on stator bars or
coils at much higher than normal operation stress levels within a short period of time to simulate
insulation aging during machine operation. The test can predict the performance of the overall insulation
system and measure the manufacturing quality. A number of diagnostic tests on stator insulation can be
conducted before and after a voltage endurance test.
Manufacturers of stator insulation could change its design, type of materials, and the manufacturing
process. The voltage endurance test can be done at the prototype and production stage to ensure the
quality consistency during manufacturing. The test gives objective assessment of the quality of stator
insulation. If coils fail the test, a remedial action may be taken by the manufacturer to improve the quality
of coil manufacturing.
Voltage endurance tests can be applied to both new coils and spare coils to check the quality and
performance of the insulation system. Spare coils have been stored for a long period of time and need to
be tested to check their performance
A set-up of the voltage endurance test station Insulation failure during a voltage endurance test at 280 hours

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2. Thermal Cycling Tests and Multi-Factor Tests

Large motors are exposed to frequent start/stop operations. Pumped-storage generators and hydro-
generators have frequent load changes. All of those operations cause rapid heating and cooling, i.e.
thermal cycling effect on stator insulation. Thermal cycling can cause
• loss of bond between copper and insulation;

• delamination and degradation of groundwall insulation;
• insulation failure.
Thermal cycling tests on stator bars and coils according to IEEE Standard 1310 -1995 and IEC standards
is to test the stator winding under multifactor (electrical, mechanical, and thermal stresses) stress aging
simultaneously to simulate normal service conditions or conditions as required. To assess the insulation
performance under thermal cycling stress as the machine experiences in service, The test insulation
system is heated and cooled at a prescribed rate for a number of cycles (e.g. 500 cycles). A number of
diagnostic tests on stator insulation can be conducted before and after a voltage endurance test.
B.2. Coil Installation and Testing

Visual examination coils and perform dimensional check, prior to installation the coils should be pre
warmed to ease installation and prevent the coils from cracking
This can be achieved by warming them to approximately 400C via an electrical welding machine or by
placing them in a covered enclosed heated with an electrical bar heater
Its recommended to stager throw the coils over 2 pitches when installing them, this should be performed
with extreme care so that the corners are not stressed.

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Testing
Electrical tests are to be performed in the stated order after lifting each ¼ of the coils and after the coils
have completely fitted and wedges
Insulation Resistance Test ( for windings at 400C)
Apply test between each phase and the frame
The test should be conducted with a 2500 V Megaohmmeter tester or above. The reading is taken after
the test has been applied for 60 second
Minimum Resistance = 100 MΩ
(note : resistance halves with every 100C increased)
Polarization Index (PI) testing for coils > 3kV

A Pi test should be conducted at each stage prior to the high potential testing. Applying constant 2500 V
dc voltage between the winding and frame for 10 minutes using a power driven megaohm meter
High Potential Testing
Connect firmly a 50-60 Hz or dc High Potential source between the winding under test and frame.
Winding to be tested as a group are connected together whilst any winding are to be connected to earth
via the frame
Coil Resistance Testing
Coil resistance reading to be compared ensuring balance between phases
Curing
The coils can be fully cured by baking them at 1600C for 16 hours after the installation has been
completed

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II ROTOR
A. ROTOR TURBO GENERATOR
A.1 Rotor winding parts

(example only, this data were taken from GE Generator 3000RPM / 237 MVA / 15.5 kV, PT PJB Unit
Muara Karang, Project Rewinding Rotor, June-August 2008)
No PART NAME MEASUREMENT REMARK

A CORE AND POLE DATA
A.1 Core length 5464mm End to end
A.2 No of Poles 2
A.3 No of slot per pole 16
A.4 Total no of slot 32
A.5 No of coil per pole 8
A.6 No of turn per coil 13
B Coil Copper bar Copper Strip
B.1 Thickness 6 mm
B.2 Wide 31.5 mm
B.3 No of cooling duct 73
B.4 Measured at top , middle
Length of cooling duct 31.0 to 32.0 and bottom bars in (1) one
slot
B.5 Measured at top , middle
Length / distance between cooling duct 43.2 to 44.5 and bottom bars in (1) one
slot
B.6 Wide of cooling duct 2.9 mm
C Inter turn insulation Material glass
C.1 No of turn insulation 1 1 (one) layer for each turn
C.2 Turn insulation thickness 0.25 mm Material : glass
C.3 Overhang insulation 0.25 mm Material : nomex
D Slot liner / Slot Cell Material : Nomex-Nomex
D.1 Slot liner length 568.8 mm
D.2 Slot Liner high 114.5 mm
D.3 Slot liner L shape length 12.46 mm
D.4 Slot liner thick 1 mm

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D.5 Slot liner qty 2 Each slot

E Material similar to 304 L
Steel wedge
equal stainless steel
C: 0.035 %
Si : 0.70 %
Mn : 1.64 %
Mo : 18%
Ni : 8.08 %
E.1 Steel wedge qty 1 row 23
E.2 End wedge qty 1 row 2
E.3 Body wedge qty 1 row 21
E.4 End wedge length 340 mm
E.5 Body wedge length 227 mm
E.6 Thickness 26 mm
F Creepage block / top packer Material NEMA G10
F.1 End ( length )
F.2 Body ( length ) 849 mm
F.3 Thickness 12.70 mm
F.4 Wide 31.6 mm
G Retaining ring insulation
G.1 Glass thickness 1.5 3 layer (out side layer)
G.2 Nomex thickness 0.8 2 layer (inside layer)
G.3 Length 480 mm
Material ; Non ferrous /
H Non Ferrous Damper bar
Aluminum
H.1 Length 5640 mm
H.2 Wide 47.33 mm
H.3 Thickness 5.02 mm
I Retaining rings Material Mn 18 – Cr 18
I.1 Outside diameter +/- 1042 mm Measured by roll meter
st
I.2 ID 1 step (locking)
I.3 ID 2nd step (end core extension) +/- 902 Measure by special tool
I.4 ID 3rd step (End winding) +/- 901.5 Ditto
I.5 ID 4th step (overhang) +/- 900 Ditto
I.6 ID5th step (stopper) +/- 883 Calculate (4th step – thick

Page 28 of 142
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of stopper)
I.7 Length +/- 690 Measured by roll meter
J End Winding blocking 7 variances Material NEMA G-11
J.1 Qty (exciter end) 105
J.2 Qty (turbine end) 106
K Sub Slot Insulation Material NEMA G-11
K.1 Length 5690 mm
K.2 Thickness 3.0 mm
K.3 Wide 34.42-34.8 mm
K.4 Cooling duct length 37.66 – 37.77 mm
K.5 Distance between cooling duct 38.7 – 38.88 mm
K.6 Locking (distance from end of exc end) 885 mm
K.7 Locking diameter 33.05 mm
A.2. Coil winding configuration and material

Cooling Duct
1 Remarks :
2
3
4
5
6 1. Steel wedge
2. Non ferrous Damper bar
3. Creepage block / Top packer
4. Coil copper bar
5. Turn Insulation NOMEX 410
6. Turn insulation “double side B-
Stage” Nomex 410
7. Slot liner Glass-Nomex
8. Sub slot insulation / Bottom
packer
7
8

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DETAIL MATERIAL FOR TURBO ROTOR
- Creepage Blocks
Creepage Blocks are long, thin strips of material that
span the length of the rotor slot.
The primary purpose of Creepage Blocks is to provide
an insulated separation between the conductors and
forging of a generator field during high potential
testing and operation in the field. Though not always
replaced during a field rewind, Creepage Blocks are
normally made from G-10 or G-11 and can be as long
as 18 feet. For creepage. Blocks longer than 8 feet in
length, a step splice can be used.
Using a special production process for homogeneous
Many Creepage Block designs require special
ventilation slots to match the ventilation
pattern of the copper bars and the turn
insulation.
Material Alternatives
The two most common materials for Creepage Blocking are NEMA G-10 and NEMA G-11 glass epoxy
laminates. These two grades are most common due to their very high compressive strength and
excellent overall mechanical strength. NEMA G-10 is a Class B (1300C) material and NEMA G-11 is a
Class F (1550C) material.
Simple Ventilated NEMA G-10 Creepage Block Compound Ventilated

NEMA G-11 Creepage Block
TURN INSULATION
Description
Turn insulation is available in slit coils, straight strips, ventilated strips, and J-strips. For
round corner field designs, JStrips or corner pieces that match the radius of the copper. Feathering the
ends of Turn Insulation prevents excessive build up when overlapping adjoining pieces.

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Turn insulation : for slit coil, straight strip and J atrip
Coil Turn Insulation is a thin strip of material used to insulate the copper turns from one another in the
rotor.
By far the most common turn insulation material, Nomex™ 410

performs very well
Nomex™ 410 at high temperatures but will grow 1-2% when exposed to
moisture or humidity.
The epoxy coating is a B-stage product that creates a strong

bond between the insulation and the copper when cured.
This material maintains the performance characteristics of
Epoxy Coated Nomexa
Nomex™ 410 while minimizing air voids between the insulation
and the copper.
This is a Class H woven glass epoxy material available in a

uncoated, fully cured version as well as with a b-stage, 1 side
coating. The uncoated version can also be sanded for the easy
Grade G-11TL
application of adhesive on-site. This material has been
commonly used on Siemens machines as well as other
European manufactured equipment
A straight woven glass fabric treated with high performance

epoxy resin. Acme 517 meets the performance requirements
Acme 517 Epoxy Fiberglass
for continuous class F (155°C) service. This material has been
commonly used on GE machines.

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This is a Class F woven glass epoxy material available with a

b-stage coating on one side. This material has been commonly
Verdur
used on Siemens machines as well as other European
manufactured equipment.
This is a Class F woven glass epoxy material available with a

Delbond b-stage coating on one side. This material has been commonly
used on European manufactured equipment.
Although Conolite™ does not perform as well as Nomex™ 410

at high temperatures, it will not grow due to moisture or creep
due to pressure. Either condition can create fitting problems
Conolite™ during installation or may cause a turn to turn failure during
operation. This material is ideal for machines with ventilated
copper turns.
Turn Insulation Materials Summary

Base Resin Total
Tolerance
Material Thickness Thickness Thickness
.002” NA .002” +/- .0005”

.003” NA .003” +/- .0005”
.005” NA .005” +/- .0005”
.007” NA .007” +/- .0005”
Nomex 410 .010” NA .010” +/- .0005”
Class H .012” NA .012” +/- .0005”
.015” NA .015” +/- .0005”
.020” NA .020” +/- .0005”
.024” NA .024” +/- .0005”
.030” NA .030” +/- .0005”
1 Side Coated 1 Side Coated 1 Side Coated 1 Side Coated
.003” .0006” .0036” +/- .0003”
.005” .0006” .0056” +/- .0003”
.007” .0006” .0076” +/- .0003”
.010” .0006” .0106” +/- .0003”
.015” .0006” .0156” +/- .0003”
Epoxy Coated Nomex
Class F 2 Side Coated 2 Side Coated 2 Side Coated 2 Side Coated
.003” .0012” .0042” +/- .0003”
.005” .0012” .0062” +/- .0003”
.007” .0012” .0082” +/- .0003”
.010” .0012” .0112” +/- .0003”
.012” .0012” .0132” +/- .0003”
.015” .0012” .0162” +/- .0003”

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.003” .002” .005” + .001”/-.0005”
.009” .001” .010” +/- .001”
Acme 517
.010” .0025” .013” +/- .001”
Class F
.012” .0025” .015” +/- .001”
.014” .0025” .017” +/- .001”
.017” .0025” .020” +/- .001”
Uncoated Uncoated Uncoated Uncoated

.008” N/A .008” +/- .0003”
Grade G-11TL
.010” N/A .010” +/- .0003”
Class H
.012” N/A .012” +/- .0003”
.014” N/A .014” +/- .0003”
.008” .0007” .0087” +/- .0003”
.010” .0007” .0107” +/- .0003”
.012” .0007” .0127” +/- .0003”
.014” .0007” .0147” +/- .0003”
1 Side Coated 1 Side Coated 1 Side Coated
Verdur 1 Side Coated
.005” .0005” .0055”
Class F +/- 10%
.008” .0005” .0085”
+/- 10%
1 Side Coated 1 Side Coated 1 Side Coated
1 Side Coated
Delbond .007” .0065” .007”
+/- .0005”
Class F .010” .0095” .010”
+/- .0005”
.014” .0135” .014”
+/- .0005”
Red – Red –
Red – Uncoated Red – Uncoated
Uncoated Uncoated
NA .005”
.005” .0005”
NA .012”
.012” .0005”
Conolite
Class B Green – Green –
Green – Green –
Uncoated Uncoated
Uncoated Uncoated
NA .005”
.005” .0005”
NA .013”
.013” .0005”
1-Side Coated 1-Side Coated 1-Side Coated 1-Sided Coated

.0135 .0007 .015” +/- .005”
Vetronite
Class F 2-Sided Coated 2-Sided Coated 2-Sided Coated 2-Sided Coated
.0156 .0007” .017” +/ .005”

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Slot Cell Insulation
Description
Slot cell insulation fits between the copper coils and

the ironslot of the rotor. These cells must have
excellent electrical properties, mechanical strength
and good heat dissipation characteristics.
Depending on the size of the rotor being rewound, the
slot cell can be a “Hard Cell” or a “Soft Cell”. Large
rotors require Hard Slot Cells that are formed to fit the
rotor slot precisely.
Smaller rotors can often use a Soft Slot Cell that will
form itself to match the rotor slot as the machine is
rewound.
Hard Cells are usually made with two L-shaped
pieces.
Each Hard Cell must be custom made to match the
radius in the bottom of the rotor slot and any steps in
the slot wall.
The shop repair company should have the ability to

mechanically form Nomex™410 into L-Shaped or U-
Nomex™ 410 Soft Cell Shaped Slot Cells with a maximum length of14 feet.
Nomex™ Slot Cells of this size are commonly used in
small rotors and exciters.
For larger machines, a combination of Nomex™ and

Glass Cloth Epoxy creates a rigid slot cell with excellent
electrical properties and good mechanical strength. Hard
Nomex / Glass Cloth Cell options include:
Epoxy Hard Cell
1) Glass Cloth Epoxy
2) Nomex™ + Glass Cloth Epoxy + Nomex™
3) Glass Cloth Epoxy + Nomex™ + Glass Cloth Epoxy

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Sub Slot Cell Insulation
Description
Gas cooled generators are designed to have the coolant
flow through the rotor slots and rotor coils.
Although this design theoretically creates a lower generator
operating temperature, it can also create winding difficulties
for the repair crew that must make sure all ventilation holes
line up properly.
The first layer of insulation in the rotor slot is the slot cell.
In gas cooled generators, the slot cell must have ventilation
holes that match the ventilation holes in the bottom of the
rotor slot.
Because fabricating a pre-formed, rigid slot cell is extremely
difficult, repair crews will utilize the three piece slot cell
system that is shown on the right. The Sub Slot Strip is a
long, thin strip of material with ventilation holes machined to
match the rotor ventilation holes precisely. It overlaps the
Slot Cells to ensure a good dielectric barrier.
Material for Sub Slot Strips must have excellent compressive strength and good machining
characteristics. As a result, most repair crews prefer NEMA Grade G-11 or G-10 FR-4. NEMA Grade G-
11 is used in Class F (155oC) insulation systems while NEMA Grade G-10 FR-4 is used in Class B
(130oC) systems
Coil Blocking
Description
Coil Blocking is used at each end of the rotor to insulate and support the coils at the end turns.
Coil Blocking must be extremely strong mechanically to resist the forces of copper growth and coil
shifting during operation.
In machines built prior to the early 1970's, asbestos phenolic was used as Coil Blocking in many designs.
Repair crews are forced to replace any components made of hazardous materials like asbestos phenolic.
Coil Blocking is normally replaced as a complete set.
This helps create proper weight distribution throughout the rotor, which is essential for balancing.

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To date, the only suitable coil blocking material in the U.S. market is laminated glass epoxy (NEMA
Grade G-10 & G-11). While both G-10 & G-11 have performed well in this application, G-11 is a Class F
material and will retain its electrical and mechanical properties better at high temperatures.
Both materials have performed well as a replacement for asbestos phenolic. For additional information on
NEMA Grade G-10 and G-11, see the data sheets included at the rear of this handbook.
The primary function of Coil Blocking is mechanical - to support and separate the copper coils. In a great
majority of cases,
Coil Blocking will fail mechanically before it fails electrically. Several of OEM / customers are now
requesting G-11 for Coil Blocking because of its Class F (155oC) temperature rating. This often adds 20-
30% to the cost of the replacement components. It is our experience that in generators with an operating
temperature of less than 100oC, G-10 Coil Blocking provides more than adequate protection. G-10 is
rated as a Class B (130oC) material.

Page 36 of 142
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Coil Blocking Design
Following are sample coil bloacking design
Retaining Ring Insulation

Description
Retaining Ring Insulation is used to insulate the
copper end turns of the rotor from the metal
retaining ring. The insulation material must have
excellent electrical properties and compressive
strength to withstand the voltage and pressure
common at the ends of a rotor.
All 60 Hz, 2 pole rotors spin at a rate of 3600
revolutions per minute. At this speed, there is
tremendous centrifugal load on the copper end
windings. To prevent displacement of the copper or
insulation materials during operation, it is important
that Retaining Rings have a very high shrink fit.
Precision machining of exotic forging material is
required to manufacture Retaining Rings.
The service workshop should capable to manufacture of Nomex 410 and NEMA G-11 in thicknesses of
.005" through .093" for use as Retaining Ring Insulation. Today, the most common alternative for
retaining ring insulation is NEMA G-11.

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Rotor Slot
INSTALLMENT
Copper bar Cooling

Sub slot duct
Cooling duct
These cooling duct

must be in line
Nomex Turn insulation
Damper bars
Creepage block Steel Wedges

Page 38 of 142
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Copper Winding and Turn Insulation
Winding Connections
Top connection Pole A

Lead connection
1 2 3 4 5 6 7 8
Bottom connection
1 2 3 4 5 6 7 8
Slipring
Pole B
Coil Top connection

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B. SALIENT POLE

Page 40 of 142
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Salient Pole Rotor Construction

Hydrogenerators and four or more pole have salient pole rotor windings.
Each field pole is constructed separately and the rotor winding made by mounting the completed poles
on the rotor rim or directly to an integral solid steel body (Figure below).
The poles are then electrically

connected to the DC supply in such a
way as to create alternating north
and south poles around the rim.
Each field pole consists of a
laminated steel core or solid steel
body, which looks rectangular when
viewed from the rotor axis. Around
the periphery of each pole are the
copper windings. Figure above are photos of a multi field pole from a small generator.
The older type of field pole design, and still the design used on generators rated at less than a few
megawatts, is called the multilayer wire-wound type. In this design, magnet wire is wrapped around the
pole (Figure above). The magnet wire usually has a rectangular cross section, and many hundreds of
turns are wound on the pole, several magnet wire layers deep. The turn insulation is the magnet wire
insulation. Looking from the axial direction, the laminations are shaped to have a pole tip (which is the
part of the rotor pole closest to the stator) to support the winding against the centrifugal force. Insulating
washers and strips are placed between the magnet wire and the laminations to act as the ground
insulation.
For larger machines, the “strip-on-edge” design is favored since it can be made to better withstand
rotational forces. In this case, a thin copper strip is formed into a “picture frame” shape, so that the
“frame” can be slid over the pole. Laminated insulating separators act as turn insulation to insulate each
copper “frame” from one another. On some copper “frames,” especially those near the pole face, an
insulating tape may be applied to the copper to increase the creepage distance. The tape and separators
form the turn insulation, and the copper “picture frames” are connected in series to make the coil. As with
the multilayer design, the winding is isolated from the grounded pole body by insulating washers and
strips (Figure below). Often, the entire pole may be dipped in an insulating liquid to bond the various
components together. For solid pole rotors, the pole tips are usually bolted on (Figure below).

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Generator rotor with bolted type, design for

medium and large generator

Page 42 of 142
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Rotor Pole Collars

Description
Rotor coils for large synchronous motors and hydro generators require a Top Pole Collar and a Bottom
Pole Collar to insulate the copper coil from the steel pole piece. Pole collars must have excellent
compressive strength and good temperature characteristics.
Glass Polyester Laminated Sheet- Grade GPO-1 (H-755) and GPO-3 has been used for Pole Collars
for several years. It is generally the most economical material available.
Grade EHC- This special grade of Glass Polyester was developed specifically for use as Pole Collars. It
has a Class F (155° C) temperature rating and excellent compressive strength. As a Glass Polyester
material, it is also relatively economical. Refer to section III for more information.
Glass Epoxy Laminated Sheet- (NEMA Grades G-10 and G-11) For applications that demand
outstanding compressive and mechanical strength, G-10 and G-11 are the best materials available.
The only significant difference between these materials is that G-10 is a Class B material (130° C) and G-
11 is a Class F (155° C). Refer to section III for more information.

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III. INSPECTIONS AND TESTING

A. INSPECTION QUALITY PLAN
Inspection date : Turbine Serial No

Inspection by : Generator Serial No
Supervision by : Field Serial No
Stator Inspection Accessibility
"O" for satisfactory "X" for unsatisfactory
Item Description N/A O X Remarks
A FRAME & FRAME EXTENSION

S01 Cleanliness of bore (oil, dust)
S02 HV Bushing
S03 Stand-off insulator
S04 Leads & Blocking
Outgoing termination Flexible connection
B END WINDING & CONNECTION RINGS
S05 Coils cleanliness (oil dust,etc)
S06 Blocking condition
S07 Ties between coils tight ?
S08 Ties between coils too dry ?
S09 Ties to surge rings tight ?
S10 Ties to surge rings too dry ?
S11 Surge-rings insulation condition
S12 Surge-rings support assembly
S13 Core-compression nuts / washers
S14 Aspalt bleeding ------ soft spot ?
S15 Tape separation -----Girth cracking ?
S16 Insulation galling/ necking beyond slot ?
S17 Insulation bulging into air duct ?
S18 Additional end wind. support hardware
S19 Insulation too dry ? ---- Flacking ?
S20 Corona activity
S21 RTD and TC wiring hardware
S22 Fan-buffle support studs

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Stator Inspection Accessibility

C CORE , SLOT & WEDGES

S23 Bar bottomed in slot ?
S24 Core condition
S25 Lamination bent in bore ? Broken ?
S26 Lamination bulging into air duct ?
S27 Greasing / red-oxide deposits on core bolts ?
S28 Ventilation duct free of materials ?
S29 Wedges condition (wedge survey)
S30 Wedges slipping out at end ?
S31 Filler slipping out of end ?

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Supervision by : Type of Rotor : Field Serial No
Retaining Ring type : Magnetic Nonmagnetic : % Mn : % Cr : x

Spindle-mounted : Body mounted :
Collector rings position : At same end At opposite ends :
Number of collector rings per polarity : One Two Three

Rotor Inspection Accessibility
D FIELD INSPECTION
R01 Rotor cleanliness [ oil, dust, iron/copper dust ]
R02 Retaining Ring Visual appearance (RR)
R03 Centering visual appearance [RR]
R04 Fan Ring Visual appearance
R05 Fretting / movement at rings fits ?
R06 Fan Blades condition
R07 Bearing journals condition
R08 Balance weights/bolts codition
R09 End wedges [touching end rings, loose ?] RR
R10 Winding wedges [touching end rings, loose ?] RR
R11 Other wedges [overheated, loose, cracks ?] RR
R12 End-Winding condition [RR]
R12 Collector rings condition
R13 Collector insulation condition
R14 Brush spring pressure and condition
R15 Brush rig condition [clean, damaged ? Etc]
R16 Shaft voltage discharge-brush condition
R17 Inner / outer hydrogen seal condition [RR]
R18 Circumferential pole slot condition [RR]
SP : Items to be found only in Salient-pole machines

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Exciter Inspection Sheet
G.1 EXCITER INSPECTION

E01 Exciter Rotor Winding Inspection
E02 Exciter Stator Winding Inspection
E03 Fuses Inspection
E04 Diodes Inspection
E05 PMG Stator Inspection
E06 PMG Rotor Inspection
E07 Hardware Scure
E08 Cleanliness
E09 Filler slipping out of end ?
B.. TESTING BASIC CONCEPT
B.1. Stator insulation aging mechanisms

A common description of the mechanisms causing aging of stator insulation groups them as “Thermal,
Electrical, Ambient and Mechanical”. This order leads to the acronym TEAM. There is large interaction of
these mechanisms: for example, mechanical formation of voids which together with high electric stress
can cause partial discharges (PD); these in turn generates heat, ultraviolet light and chemicals such as
ozone, and thereby encourages mechanical wear at the attacked insulation surface by thermal and
ambient stresses.
Thermal deterioration of the organic binding component of the insulation, particularly in air-cooled
machines, is a continual process, often simply modeled with an Arrhenius-rate reaction, i.e. an
exponential relation of rate to temperature above a minimum value. The deterioration leads to more brittle
insulation material, which in turn can increase the effect of vibrational aging.

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Thermal cycling may cause stresses and movement of whole bars (complete with groundwall insulation)
axially relative to their slot, or for quick changes in load the forces from differential expansion may cause
internal movement in the bar, between conductors and insulation. The copper windings are the main
heat-source when at high load, so these warm up faster than the surrounding iron and reach a much
higher temperature, besides having different coefficients of thermal expansion. Mechanical stress and/or
movement occurs therefore during changes of load.
There are large forces between conductors even with the currents of normal operation; separate
conductors within a bar, separate bars within a slot, and nearby connections in the end-winding region all
experience forces that alternate at twice the power frequency and that can damage the insulation in
regions where there is looseness that allows movement. During a short circuit the forces can be many
times greater, possibly causing internal damage that initiates longer-term degradation; the bars must be
very firmly held in place particularly in the end-winding regions where they do not have the stator iron and
slot-wedges to constrain them.
 Electrical stress can cause electrical treeing, a change in the insulation material along channels in
the field, which may grow enough to cause a breakdown of the insulation.
 Partial Discharge activity, although not rapidly damaging to mica insulation when discharges are
small, wears the binding material by the effects of local heating, ultra-violet light and production of
reactive chemicals such as acids and ozone.
 The semi-conducting coating of the stator bars may wear out, due to the chafing from vibration in
the slot and from thermal expansion, or due to arcing from lamination short-circuits. The end-
winding stress-grading materials may also become less effective with time, leading to surface PD.
Tape-applied grading is found to be more durable than paints. Stress between windings in the
end-winding region, due to bad design or to movement, can also cause PDs. Conductive dirt on
the surfaces of the end-windings, in the high surface field, may cause PDs that wear the surface.
 Different ageing effects respectively ageing mechanism caused by electrical, thermal, mechanical,
chemical or ambient loads change the properties of the electric insulation system and it comes to
an degradation of the material. In the final stage of the ageing the electric insulation breaks down
and the equipment falls out. For this reason different methods and measurements for the
evaluation of the condition are used.

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B.2. BASIC INSPECTIONS LEVEL

Inspection/testing or monitoring of generator conditions can be carried out when machine off line with full
assembled or rotor pull-removal and on line, following are condition monitoring step by step criteria.
Monitoring Monitoring / Inspection activities Degradation limit Operating

Confidence
LEVEL
Generator On Line / Operation pass

- No of Start-Stop ≤ 5% 65%
Monitoring
- Vibrations
LEVEL 1 - Thermal No
- Loading profile
- On lone Partial Discharge (if available) When
degradation >
5% to 10 % do
Gen. Shutdown / Off Line (full insp to level 2.
assembled)
Monitoring - Inspection LEVEL 1 pass
- Test Tangent Delta and Capacitance (stator) ≤ 10% 80%
LEVEL 2 - Test Off Line PD ( stator)
- Test PDC (stator/ rotor) No
- Test IR / PI (stator / rotor)
- Test Winding DC Resistance (stator / rotor) When degradation
- RSO and AC Impedance (rotor) > 10 % to 30 % do
insp to level 3.
Gen Shutdown with Covers removal

pass
- Inspection LEVEL 2
Monitoring ≤ 30% 85%
- Borescope inspections
LEVEL 3 - Endwinding inspections (PD Probe) No
When degradation >

50 % do insp to level 4
Gen shutdown with rotor removal
- Inspection LEVEL 3
Monitoring - Coupling Resistance
- Natural Frequency
LEVEL 4 Pass with 95%
- Wedge mapping
- Digital EL CID repair
- NDT on RR‟s, Steel wedge,
Magnetism , journal shaft, Bearings,
(rotor) / for turbine generator only

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B.3. Life time analysis
UTS (Ultimate Tensile Strength) = f (Q1,

Q2, Q3, void content, temp, PD, IQ
index)
Insulation Improvement Goal
60% is
critical
value

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The machine insulation is subjected to

constant thermal stress that causes aging
as given by the Arrhenius chemical
degradation rate equation and charts for
different insulation class. Besides this,
there are cyclic thermal stresses caused
by frequent starts/stop of the machine.
This causes reduction in tensile strength
of the insulation, which can be expressed
in terms of residual breakdown voltage
(RBDV). The basic Arrhenius curves are
modified to account for the operational
hours and starts/stops as shown.
It is assumed that the BDV for new
machines is 100%. There is initial
reduction in BDV (shown by BDV1) due
to stresses caused by heating of
windings and insulation, corresponding to
the operating hours. The stresses are
high during starting and stopping conditions, which further reduce the BDV (shown by BDV2). The value
of 60% for BDV is taken as the critical value, below which the machine is at high risk of insulation failure.
C. INSPECTION AND TESTING BASIC CONCEPT EXPLANATION

C.1 Monitoring Level 1 ( Generator On Line )
Condition monitoring on generator when generator in operation (on Line), can be performing by
monitoring :
1. Thermal / temperature
2. Vibrations with thermal sensitivity test when generator has suspected vibration due to electrical
vibrations such as vibration increase when generator MVAR increases.
3. On Line Partial Discharge (if provide)
C. 2 Monitoring Level 2 , when generator shutdown in full assembled with termination

disconnected.
Inspection level 1 plus the following test as bellows.
C. 2.1. Electrical Test Stator

1. Insulation Resistance Test
2. Polarization Index

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3. Winding DC Resistance
4. PDCA (Polarisation Depolarisation Current Analysis)
5. Tan Delta (Tip-up and Capacitance)
6. Off Line Partial Discharge Test with C – Coupler Sensors
C. 2.2 Rotor Test
4. RSO (Recurrent Surge Oscillation)
5. AC Impedance
6. PDCA (Polarisation Depolarisation Current Analysis
C. 2.3 Exciter
4. PDCA (Polarisation Depolarisation Current Analysis)
C. 3 Monitoring Level 3, When Generator Shutdown with partial parts removal ( top half cover
removal)
Inspections Level 2 , plus the following tests
1. Endoscopic Inspections for Endwinding Stator and Rotor underneath retaining rings
2. Endwinding Stator Partial Discharge with Probe
C. 4 Monitoring Level 4, when Generator Shutdown with Rotor Removal.

Inspections Level 3 plus the following test.
C. 4.1. Rotor Removal & Re assembly

1. Alignment record
2. Rotor removal and re inserting
3. Re assembly all parts and re alignments by using laser optic
4. Running test / commissioning

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C. 4.2. Stator
1. Visual Inspection with Borrescope camera, incl core loose / tight inspections, compression bolts,
surge rings, support rings, end winding support, etc.
2. Frequency Domain Spectroscopy (FDS) test
3. Natural Frequency Test
4. Coupling Resistance Test
5. Non Linear Analysis Test
6. Stator Wedge Mapping
7. Digital ELCID Test
C. 4.3 Rotor Winding

1. Visual Inspection with Borrescope camera
2. NDT on Retaining Rings, Journals, bearings, etc
3. Demagnetizing / degaussing on the rotor shaft, couplings, bearings, etc
C. 4.4 Exciter
1. Visual Inspection
2. (for sliprings) Inspection to Collector Ring, Carbon brushes, Springs, Holder, etc
3. (for Rotating diodes), incl insp of Diodes, fuses, surge, etc
C. 4.5. Winding Improvements

1. Cleaning, drying, re insulating coating for Stator / Rotor / Exciter
2. Minor or temporary repair on stator wedges by using Epoxy Resins
3. Minor Repair on End Winding (blocking coils, ties, etc)
4. Stator wedges removal and replacements by using NEMA Li G 11 or DELMAT Epoxy 68660 or
LSBC ( Low Shrink Black Canvas) or specified by customer
5. Anti corona injection / improvement of conductive layer on the winding by injecting conductive
painting entire slot.

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D. STATOR TESTING
D.1. Insulation Resistance and Polarization Index, IEEE 43-2000

The Insulation Resistance test is purpose for this test is the measurement of the ohmic value between
the conductors and the iron core [normally grounded]. The measurement in the Mega Ohm region after
the winding is subjected to a DC voltage for 60 second. The insulation resistance test is refer to IEEE
transaction No. 43 – 2000 standard.
Voltage test applied:
Winding Rated Insulation Resistance

Voltage (V) Test Direct (V)
<1000 500
1000-2500 500-1000
2501-5000 1000-2500
5001-12,000 2500-5000
>12,000 5000-10,000
Minimum Insulation
TEST SPECIMEN
Resistance
For most windings made before about 1970, all field

R1 min = kV+1
windings, and others not described below
For most dc armature and ac windings built after about

R1 min = 100
1970 (form wound coils)
For most machines with random -wound stator coils

R1 min = 5
and form-wound coils rated below 1kV
1 - IR 1 min is the recommended minimum insulation resistance, in megohms, at 40 0C entire machine

winding
2 - kV is the rated machine terminal to terminal voltage, in rms kV
Interpretation
What constitutes a „good reading‟ and a „bad reading‟ depends on the nature of the insulation system and
the component (stator or rotor) being tested. Until 2000, the minimum R1 and the acceptable range for PI
was essentially the same for all types of stator winding insulation. However, it has been recognized that

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the modern insulation materials in random wound and form wound stators have essentially no conduction
current (as long as there are no cracks or pinholes). Thus it is possible for a clean, dry, form wound
stator winding to have an R1 that is essentially infinite – greater than 100 GW. With an R1 of infinity,
calculations of a realistic PI are dubious. Such high R1‟s are not likely in systems made before the
1970‟s. Consequently, the maintenance person needs to establish the type of insulation used in the
winding, or at least the approximate age of the winding, before interpreting IR and
PI results.
summarizes how to interpret IR and PI results in stator and rotor windings. The distinction between older
and modern insulation systems was set at 1970, although this is somewhat arbitrary. Of note in this table:
1. If R1 is below the indicated minimu m, the implication is that the winding should not be subjected
to a hipot test, or be returned to service, since failure may occur. Of course if historical experience
indicates that a low R1 is always obtained on a particular winding, then the machine can probably
be returned to service with little risk of failure
2. The minimum R1 is the value corrected to 400C.Unfortunately, any more than 10-200C correction
is unlikely to be valid.
3. The minimum acceptable R1 is much lower for old stators than new stators, and it depends on
voltage class. For modern stators, the minimum acceptable R1 only depends on whether it is a
form wound or random wound stator.
4. For modern form wound stators, if a very high R1 is measured (say greater than 5 GΩ), then PI is
not likely to indicate anything about the winding. Thus, one can save time by aborting the test
after the first minute of testing.
5. If the IR or PI is below the minimum in a modern stator winding, it is only an indication that the
winding is contaminated or soaked with water.
6. If a high PI result is obtained on an older stator winding, then there is a possibility the insulation
has suffered thermal deterioration. This occurs because thermal deterioration fundamentally
changes the nature of the insulation, and thus the absorption currents that flow. The insulation
has changed in an asphaltic mica winding if the asphalt has been heated enough to flow out of
the groundwall.
In general, the IR and PI tests are an excellent means of finding windings that are contaminated or
soaked with moisture. Of course the tests are also good at detecting major flaws where the insulation is
cracked or has been cut through. In form wound stators using thermoplastic insulation systems, the tests
can also detect thermal deterioration. Unfortunately, there is no evidence that thermal deterioration or
problems such as loose coils in the slot, can be found in modern windings
Polarization Index [PI ] test is purpose, to evaluate how clean and dry a winding is. The Polarization
Index [PI] is the ratio between the resistance reading at 10 minutes and the reading 1 minute. Winding
with the low PI are usually relate to moisture and / or dirt contamination. The recommended minimum PI
values with refer to EPRI EL – 5036, or IEEE 43 -2000 are:
- Class A insulation : 1.5
- Class B insulation : 2,0
- Class F insulation : 2,0
* EPRI : Electric Power Research Institute

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D.2. Winding Resistance

During this test, the measurement of the ohmic value between terminals winding is carried out. Given the
relatively low series dc resistance of winding.
The purpose of this test is to detect shorted turns, bad connections, wrong connection and open circuit.
Acceptable test result consist of three resistance value each phase to be balanced in according standard.
The machine should be in room temperature when the test is performed. test should be applied on the
Stator winding and rotor winding, test will be referred to International Standard NEMA MG-1, IEEE and
factory measurements.
The resistance should be corrected to temperature:
Rt2 (t1  k) When the resistance, Rt2 : of a winding has been determined by test at winding
Rt1  temperature,
(t2  k) t1 : the resistance may be corrected to a specified temperature,
t2 : the temperature test of winding
k : is 234.5 for 100% IACS conductivity copper, or 225 for aluminum, based on a volume conductivity of
62%
D.3 Hi Pot – IEEE -56

High Potential Testing
A high potential test is a pass/fail dielectric examination of the winding insulation system. A high
potential test can be performed utilizing either AC or DC test equipment. Both types of tests have their
very own specific characteristics, benefits (both positive and negative), and results.
MAINTENANCE AC HIPOT TEST

IEEE 56 is an extensive guide on various tests and inspections that can be performed on rotor and stator
windings, as well as a review of the major repair methods.
The document saw its last major revision in 1977 [2], and is now the subject of a complete revision by a
working group that is combining IEEE 56 with IEEE 432, so that one guide will cover all form wound
motors and generators. The revised version of the standard will probably be published in 2004.
Although IEEE 56 discuses many tests, of relevance here is the maintenance AC hipot. A hipot test is a
„high potential‟ applied to the winding. In order to find gross flaws in the winding, the „high potential‟ test
voltage is normally higher than what the winding sees in service. The basic idea is that if the winding
does not fail as a result of the high test voltage, the winding is not likely to fail anytime soon due to
insulation aging when it is returned to service. If a winding fails the AC hipot test, then a repair or rewind
is mandatory, since the groundwall insulation has been punctured.

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The AC hipot is similar to the DC hipot (section IV), with the exception that power frequency (50 or 60 Hz)
voltage is used. Sometimes 0.1 Hz AC is also employed, as described in IEEE 433. Both commissioning
(acceptance) and maintenance AC hipot versions of the test are in use. This test is most commonly
applied to form wound stator windings.
Purpose and Theory

The purpose of this test is to determine if there are any major flaws in the groundwall insulation, before a
winding enters service (commissioning or acceptance hipot test) or during service (maintenance hipot
test). The principle is that if there is a major flaw in the insulation, a high enough voltage applied to the
winding will cause insulation breakdown at the flaw. By IEC 60034 and NEMA MG1 standards, all new
windings (original or rewound) are subjected to a successful hipot test prior to being accepted by the
customer. Of course the main problem with hipot testing (both AC and DC – see the next Section) is that
the winding may fail. If failure does occur, then either:
1. The insulation that punctured must be replaced.
2. The coil with the puncture is removed from the circuit.
3. The coil or even the complete winding is replaced.
These are all expensive alternatives, and all involve a delay in placing the machine in service. Since a
hipot test can be destructive and delay a return to service, many people decide not to perform a
maintenance
AC hipot. The rationale is that the hipot test may cause a failure that would not occur for a long time in
service, resulting in rewinding or significant repairs before they are really needed. This is true. However,
the proponents of hipot testing argue that for many critical machines, an in-service failure (that could
have been prevented if a hipot test was done) can result in a greater disruption to plant output than a
hipot failure.
For example, the in-service failure of a critical pump motor in a petroleum refinery can stop production for
days or weeks, and cost as much as $1M per day. Also, an in-service fault can sometimes cause
consequential damage such as stator core damage, a fire or coils being ejected from the slot, resulting in
much higher repair costs. Thus, whether an AC hipot is performed as a maintenance test depends on
how critical the machine is to the plant, the availability of spares, and the philosophy of plant
management to avoid unexpected plant shutdowns.
With the AC hipot, the voltage distribution across the thickness of the groundwall insulation is the same
as the distribution in service since the applied voltage is AC, and capacitances determine the distribution.
NEMA MG1 and IEC 60034 define the AC acceptance hipot level as 2E + 1 kV, where E is the rated rms
phase-to phase voltage of the stator. IEEE 56 recommends the AC maintenance hipot be 1.25 to 1.5E
[2], and this is unlikely to change in the current revision. For example, if the guidelines in IEEE 56 are
used, the AC hipot test voltage for a 4.1kV motor would be about 6kV rms. The hipot test is applied
between the copper conductor and the stator or rotor core.
The AC hipot will age the insulation. In most cases, the hipot voltage is sufficiently high that significant
partial discharge activity will occur. These partial discharges will tend to degrade the organic components
in the groundwall, thus reducing life. However, calculations based on IEEE 930 indicate that insulation
deterioration from a 1-minute AC hipot test at 1.5E is equivalent to about 235 hours or 10 days at normal
operating voltage. Therefore, the life is not significantly reduced by a hipot test if the expected life is
about 30 years

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Interpretation
A winding either passes or fails the AC hipot. There is no other diagnostic information provided. If the
winding fails, as determined by the power supply circuit breaker tripping, then repairs, coil or winding
replacement is required.
IEEE 95 - DC Hipot Test
Test Methods
There are several different methods for performing a DC hipot. Most are reviewed in IEEE Standard 95,
and the 2002 version highlights a new variation of the DC hipot called the DC Ramp test. Some of the
variations reduce the risk of a failure during the test, and some also give information of a diagnostic
nature.
For all types of DC maintenance hipot test methods, the critical decision to be made is the maximum test
voltage. For form wound stator windings, IEEE 95 gives guidance. It suggests that the maintenance hipot
should be 75% of the acceptance hipot level. NEMA MG1 and IEC 60034 stipulate that the DC
acceptance hipot be 1.7 times the AC hipot acceptance level of 2E+1 kV, where E is the rated rms
phase-to-phase voltage of the stator winding. After performing the arithmetic, it works out that the DC
maintenance hipot level should be about 2E. That is, a 4.1 kV winding would be tested at about 8 kV, DC.
This level was originally suggested since it approximates the highest likely over voltage in the motor that
can occur if a phase-to ground fault occurs in the power system. Consequently, a maintenance hipot just
reproduces, in a controlled, off-line fashion, the over-voltage a stator can see in service. The idea here is
that if the winding can survive this hipot, it is unlikely to fail in service due to a voltage surge created by a
power system fault.
Conventional DC HiPot
In the conventional maintenance DC hipot, a suitable high voltage DC power supply (available from many
suppliers) is connected to the winding, either at the switchgear, or at the machine terminals. The DC
voltage is quickly raised to the test voltage and held for either 1 minute or 5 minutes.
After this time, the voltage is quickly lowered, and the winding is grounded. If the insulation is sound,
there will be no high current surge, and the power supply circuit breakers will not trip. If the power supply
breaker trips, then it is likely a puncture has occurred, since the insulation resistance will have
instantaneously dropped to zero, which causes an „infinite‟ current to flow (by Ohm‟s law), and the power
supply can not deliver this „infinite‟ current. Circuit breaker tripping is an indication that the winding has
failed and winding repairs or replacement is required.
Step-Stress Hipot
A variation is to use the same supply as described previously, and gradually increase the voltage in
either equal or unequal steps. For example, the DC voltage can be increased in 1 kV steps, with each
voltage level being held for 1 minute before it is increased again. One then measures the DC current
after the end of each step (since by this time the capacitive current will have dropped to zero), and plots it
on a graph of current versus DC voltage. Ideally, the plot will be a line with a gentle upward curve.
However, sometimes the current increases abruptly above a certain voltage. This may be a warning that
the insulation is close to puncturing.

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If the tester acts rapidly, the test can be aborted (voltage turned off) before a complete puncture occurs.
Experience shows that warning is likely if the flaw is in the endwinding, but little or no warning is given if
the flaw is within the slot. By carefully applying this test, a hipot failure may be avoided.
However, if the voltage at which the current instability was detected is below operating voltage, there is a
high risk in returning the winding to service without repairs.
D.4. EL CID ( Electromagnetic Core Imperfection Detection)

Electromagnetic Core Imperfection Detection (EL CID) is used to check the integrity of inter-lamination
insulation for stator cores of generators and motors. A fault current occurring within the laminated stator
core results in a hot spot and can cause a catastrophic failure of a generator and motor in service. An EL
CID test can :
• detect faults and defects in the stator core;

• check effectiveness of core repairs;
• test the stator core before and after a stator rewind to check any damages caused by rewind;
• check the quality of a new stator core;
• trend the stator core condition.
In comparison with a traditional loop (ring flux) test, an EL CID test offers the following
benefits:
• Uses a portable excitation transformer instead of a large excitation transformer in a loop test to
considerably reduce test cost;
• Saves 30% of test time and labor cost of a loop test.
• Conducts low power testing (EL CID uses only 4% of the rated magnetic flux) to avoid further
damage to fault areas;
• Does not have safety concerns to test personnel;
• Records test data by a computer for trending of test results.
• Provides an easy and in-expensive test method to check the quality of a core repair or a re-
wedging operation.
Core analysis by using Digital EL CID Technology On

Alstom Generator 46.25 MVA.

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a
b
Fig.a ELCID Scanning on stator core

Fig b. ELCID Visualization Record
Fig.c ELCID Instruments
d
Fig.d and e ELCID overall record

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D.5. Insulation Dissipation Power Factor and Tip Up
Theory
Power factor testing of rotating machinery is a non-destructive AC test performed off-line at apparatus
frequency. When a 50 Hz voltage is impressed across generator stator insulation, the total current that
flows is similar to that of any capacitor. The total current has two components: a relatively large
capacitive current (ic) which leads the voltage by 90°; and a smaller resistive current (ir) which is in-
phase with the voltage. The dielectric of this simulated capacitor is the insulation system which is
embedded between two electrodes, the high voltage copper conductors and the stator iron core.
Definition of dielectric variable
Total charging current
tan ∂ = ir / ic
The power factor is the Cos Ø = ir / it. Power factor is a dimensionless quantity and thus can be
compared amongst different volumes of insulation systems. It is a measure of the dielectric losses of the
insulation and provides valuable information about the insulation quality. Power factor is performed per
phase at incremental voltages starting at a voltage below corona inception and continuing up to the line-
ground voltage rating of the machine and possibly 20% over.
Tan Delta Test Circuit
The leakage current IL through the insulation stator winding consist of capacitance current a loss current
as describe on figure.On the other hand capacitance “C” is filled up the gas to make energy loss in
capacitive is negligible.

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Power factor Tip-up is defined as the power factor measured at the line-ground voltage minus the low
voltage power factor (typically performed at 100% and 20% of the line-ground voltage). Since all dry type
insulation systems contain voids, the power factor will increase with an increase in test voltage. The
increases in power-factor as a function of voltage are due to the ionization of the gas in the voids of the
insulation system. An insulation system with excessive voids will have a higher power factor tip-
up.Excessive voids may be due to the aging of the paper tape or of the bonding material in the insulation
system. Aging of these materials leads to a reduction of physical strength, and thus the production of
voids. Once excessive voids are present, partial discharge will occur which also damages the bonding
materials. The degradation of the insulation system may occur internally or on the surface of the coil/bar,
due to loose coils within the slot, deterioration of the semicond grading paint and/or inadequate coil
spacing .
Dissipation Power Factor
12
Tan δ
10
Decreasing
Tan δ
ΔTan δ
Increasing
6 0.2 0.4 0.6 0.8 1.0
U / Un
Tan delta4 performed by increasing and decreasing test with 20% increment voltage.
D.6. Partial Discharge

2
Partial Discharge Measurements
Introduction
A problem common to machines with thermoplastic insulation is that the normal thermal cycling is causes
coil movement in the slot, tend to generate crack within the ground wall insulation.
A tape separation is a separation of tape covering the wall insulation of the coil due to axial expansion
and contraction of the conductors and the opposing forces of the slot applied to the wall insulation.

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In some cases only the armor tape is separated, in other cases the mica-tape comprising the ground-wall
insulation is also affected , when this occur a few layer may be affected and the whole tape will move
creating “ a neck” in the coil.
Deterioration of Stator Coil Insulation Condition
Thermal Operating Temperature
Electrical Surge voltage
Mechanical Electromagnetic vibration
Damage of Stator Coil Generating the VOIDS

Insulation
PARTIAL DISCHARGE
Corona activity
Corona is define as the ionization of gas when exposed to an intense electric field , the discharge have a
wide range of frequencies [ 40 kHz to 100 MHz ].
Partial Discharge (PD) in the large generator application, is usually associated with the high voltage
stator conductor bars.
Corona activity in the rotating machine :
Surface discharge due to Corona at end winding ( End-winding Discharge )

Internal discharge due to Corona at inside of the insulation ( voids or delamination)
Slot discharge Corona at ground-wall insulation resulting from loss contact between bar and
core. (damaged on the semiconductive coating on the stator bar)
Surface discharge due to Corona at overhang of winding resulting from bar vibration
Partial discharge (PD), can be detect when generator in operation or standstill or shut down corona
inception and extinction measurements provide a non-intrusive indication of the void content and other
problems, which may be present in a stator bar or a coil. Partial discharge measurements to identify
insulation defects which could be caused by loose contact of semiconductive to ground and or defect of
the semiconductive insulation.
Partial discharges are a symptom and sometimes a cause of many types of stator winding insulation
system deterioration mechanisms. Thus it is not surprising that the on-line measurement of partial

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discharges has been used to assess the need for maintenance in stator windings since .More
particularly, off line / on line PD measurement has been able to determine if the electrical insulation is
deteriorating due to loose coils in the slots resulting in insulation abrasion; thermal deterioration or load
cycling leading to insulation delamination; and electrical tracking caused by partly conductive
contamination of the endwindings .
Many methods are available to measure the PD activity in operating machines. The electrical techniques
all rely on monitoring the current or voltage pulse that is created whenever a partial discharge occurs.
Partial Discharge Measurements

On Line Partial Discharge with C – coupler sensors
On Line Partial Discharges with RFCT (Radio Frequency Current Transformer)
On Line Partial Discharges with RTD‟s sensors
Off Line measurement with C – Couplers Sensors
Off Line measurement with probe
Off Line Partial Discharge Measurements.
Corona probe measurements

Corona probe testing can pinpoint partial discharge location in each slot. It supplements on-line/off-line
partial discharge tests by precisely locating partial discharge to a particular coil or a spot. The corona
probe can also be used as a testing tool to measure levels of PD activity. Corona probe testing can be
performed either with the rotor in or out of the machine.
Test method
PD probe tests performed on the generator to identify the bad bars. The probe scanned each slot to
pinpoint partial discharge locations in each slot. An HV transformer used to apply Un/√3 kV to each
phase of the generator. While one phase was energized with the other two phases grounded, the probe
scanned only these slots in the energized phase.
The PD levels in mA is the representative of corona
activities in the winding normally there is a concern over 20
mA, slot discharge can also develop surface discharge if
the air gap of coil to slot is big enough. Surface discharge
can produce excessive heat to cause further thermal
damages to the semi-conductive coating and the fillers.

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Loose wedge also caused movement of the bars in the slots and abraded away the semi-conductive
coating, therefore resulting in slot discharges and surface discharges which can lean to insulation
failures.
Off line PD test with bar to bar scanning
Off line Partial discharge with bar

to bar scanning on 87.5 MVA / 13
KV Alstom Generator, to evaluate
Partial Discharge activities at each
coil bar stator , stator winding has
energized by external HV power
supply Un / √3. With floating systems, phases not tested are grounded.
Partial Discharge Measurements with C – Coupler Sensor

Test method.
The set-up of the off-line PD test is shown in Fig. below, PD Tester used to apply Un/√3 kV or line-
to-ground voltage to the stator winding, the low voltage lead and the test-set ground lead were
connected to the machine ground. A resonant reactor (RR) used to neutralize the capacitive current
of a Stator generator. Using the ground-specimen test mode, each phase was tested with the other
two phases grounded.

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ON LINE PARTIAL DISCHARGE
Six capacitive couplers, two couplers per phase, installed in the stator generator. One coupler was
installed at the isolated phase bus close to the generator and the other at the isolated phase bus with
some distance from the first one. The two capacitive couplers on each phase work as a pair to eliminate
noise from outside the generator using the “time-of-flight” technique. A partial discharge analyzer (PDA)
can perform PD tests during normal machine operation. PD test results are displayed in the form of pulse
polarity, magnitude, number, and phase position. Subsequent data analysis provides further information,
such as, maximum PD values, normalized quantity number (NQN), historical trending of PD test results,
variation of PD activity with temperature and load, etc. The three-dimension graph the PD magnitude, PD
pulses per second and the PD position against the 50 or 60 Hz sine wave.
The positive and negative pulse distribution has an equal distribution, this indicates that there were partial
discharges within the groundwall insulation. The internal voids within groundwall insulation, created by
poor impregnation during manufacture or by other aging mechanisms during machine operation,
produced groundwall partial discharges under high voltage stress. Groundwall discharges can occur at
delaminations or areas where bonding material is incompletely cured.
Interpretation
The key measurement in a PD test is the peak PDmagnitude Qm, i.e. the magnitude of the highest PD
pulse. This can be measured in several units:
1. picoCoulombs (pC) if a laboratory PD measurement device is used. pC is a measure of the
apparent number of electrons that was involved in each discharge.

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2. millivolts (mV), where the PD magnitude is measured with an oscilloscope or electronic pulse
magnitude analyzer (PMA). A PMA counts the number of PD pulses of each magnitude range.
3. milliamps (mA) if the PD pulses are measured with a high frequency (ferrite core) current
transformer and displayed on an oscilloscope.
4. decibels (dBm) if a frequency spectrum analyzer records the pulses.
The detected PD magnitude at the stator terminals of a PD pulse within the winding depends on a large
number of factors:
1. The size of the defect. In general, physics indicates that the larger the volume of the defect, the
larger will be the detected pulse.
2. The capacitance of the winding. If the winding has a large capacitance, the impedance to ground
at high frequencies will be very low. Thus most of the PD pulse current is immediately shorted to
ground, leaving little to be detected at the stator terminals.
3. The inductance between the PD site and the PD detector. The pulse will be attenuated as it
propagates through the winding to the terminal. In general, the further the PD site is from the PD
detector, the lower will be the magnitude detected at the machine terminal
These plus other effects make it difficult to define a „high‟ PD magnitude that indicates that a winding has
serious deterioration [6]. The PD test is thus a comparison test.
One can determine which phase has the highest Qm, and thus which phase has the greatest
deterioration. One can also compare several similar machines to see which has the highest PD. Finally,
one can compare the PD from the same stator over time, i.e. trend the data. In general, if the PD doubles
every 6 months, then the rate of deterioration is increasing.
Direct measurement of the PD pulses also enables one to measure how widespread the PD is. Studies
show that as many as 10,000 PD pulses may occur per second in a stator winding. It seems that a single
defect only produces at most 1 or 2 PD pulses per half ac cycle.
Thus if only a few hundred PD pulses are occurring per second, then there are only a few PD sites in the
winding, and the deterioration is localized. If there are 10,000 PD pulses per second, then there are
thousands of PD sites, and the deterioration is widespread. The pulse count rate can be easily measured
with a pulse magnitude analyzer, which is incorporated into most modern commercial PD analyzers.
If there is one dominant deterioration mechanism in a winding, the PD test can sometimes give the
approximate location of the deterioration within the groundwall.
1. If the positive PD pulses (which by definition occur in approximately the negative half of the AC
cycle) are larger than negative PD pulses, then it is likely the PD is occurring on the surface of the
coil (due to loose coils or defective semiconductive coatings).
2. If the negative PD is predominant, then the PD is most likely occurring at the copper.

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3. If there is no polarity predominance or the positive and negative pulse distribution has an
equal distribution, then the PD is likely to be between the groundwall insulation layers. The
internal voids within groundwall insulation, created by poor impregnation during manufacture
or by other aging mechanisms during machine operation, produced groundwall partial
discharges under high voltage stress. Groundwall discharges can occur at delaminations or
areas where bonding material is incompletely cured.
Unfortunately there is no standardized measurement unit. In Europe, there is a tendency to use pC, in
spite of various standards indicating that the pC calibration procedure is not intended for use in inductive
apparatus [6]. In North America, mV and dB are more common
Pulse Discharge Maximum Ref To TOSHIBA TIL No. ECS -990506P (Technical Information Letter For
Preventive Maintenance of 125 and 250 MVA Turbine Generator.
Qmax = 10 000 pC for machine with voltage E ≥ 6.6 KV
Qmax = 4000 pC for machine with voltage E = 3.3 kV
Ref :
Testing of Large Electric Generator for Suitability of Services.Clyde V. Maughan P.E. Maughan
Engineering Consultant. Schenectady, New York
Qmax = 5000 pC, is interpreted as insulation deterioration.
Qmax = 500 mV, is interpreted as insulation deterioration.
IEC 60270, defines the repetition rate for Qm to be 50 or 60 pps

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Figure References.
Document references Stator coils burnt out due to corona activities: Our Project Rewinding Stator
Generator ALSTOM 87.5 MVA / 11000 KV.
Stator filler burn-out due to PD activities Overheating on the stator bar due to corona
activities, figure was taken after stator wedge
removal (ALSTOM 87.5 MVA, PT DSS)
Insulation winding construction and coil arrangement in

the stator slot
Winding are designed with side ripple , to maintain

Winding are not designed with side ripple,
in good contact between bar to core, Toshiba
loose contact can occur due to damaged
Generator 250 MVA,
of semicond coating ALSTOM Generator
87.5 MVA

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D.7 Natural Frequency
End Winding Frequency Mapping
Premature winding failure may occur due to excessive end winding vibration. Large turbine generators
and hydro generators are most susceptible. Routine measurement of vibration amplitude and frequency
is important in detecting looseness, which can lead to fatigue and failure of copper conductors and
insulation systems.
D.8. Contact coefficient ( Coupling Resistance)
Loose contact between semiconductive to core normally

Contact resistance ground can produced high resistivity in the corona protection
measured from bar winding. Surface Resistivity of Corona Supression Layer Must
body to core
between :1.0 - 6 kΩ / Square, with idle average within 2-4 k Ω
Contact restivity of corona suppression can be measured
through end winding beyond the stator core and vent holes of
stator core or direct contact winding to core. with stator wedge
removal

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D.9 PDCA (Polarisation Depolarisation Current Analysis)

The PDCA is a complementary test to analysis of charge
storage phenomena on the winding normally is charged by
megger for 1000 secs at 2.5 kV or 5 kV (depending on rated
voltage of the machine). It is then discharged through
resistance for 1000 secs .
PDCA used to identified Charge Storage with time constant.
Q1,T1 (charge storage in the whole winding) Charge
Storage with time constant.Q2,T2 identified Polarisation and
interfacial polarization in the slot region, Q3,T3 identified
Interfacial polarization in the endwinding region.
The procedure uses DC voltage to test the specimen. From
the DC voltage step a polarization / depolarization current
results in the insulating medium, which decays
exponentially. The temporal process, the size and the shape
of the PD current give information about condition and
characteristic values (oil conductivity, polarization time
constants).
Fig. Measurement and the principle distribution of the
current
It is a pulse-like current during the instant of voltage
application, which decreases during the polarization
duration to a certain value given by the DC conductivity of
the insulation system. After the polarization duration voltage
supply is interrupted and the test object is grounded. Thus,
the discharging current jumps to a negative value, which
goes gradually towards zero.
Q1 T1 :_Charge storage: The charge storage takes place due to various mechanisms such as
Q2 T2 : Space charge polarization: The alignment of electric dipoles within the insulation on
application of electric field results in accumulation of charges in a region such as slots and in the
endwinding.This is called space charge polarization.
Q3 T3 : Interfacial polarization: The migration and accumulation of charge between two different
dielectrics that have different dielectric constants (such as that between machine insulation and oil
contaminant) gives rise to interfacial polarization.

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Q2T2 : Space charge

polarization and
Interfacial polarization
In SLOT region
Q3T3: Interfacial
polarization in
ENDWINDING region
E. ROTOR TESTING ( APPLIED FOR TURBO AND SALIENT POLE)

E.1. Insulation Resistance, Polarization Index and Winding Resistance , Polarisation
Depolarisation Analysis (PDCA) test are performing with same procedure for the Stator winding
test,
E.2. Turn to turn short Test
Theory:
Shorted turn in the rotor winding are associated with turn shorts on the copper winding as opposed to
turn to ground faults. Rotor winding shorted turns or inter turn –turn shorts can occur from an electrical
break down of the inter turn insulation , mechanical damaged to the inter turn insulation allowing adjacent
turn to turn contact or contamination in the slot which allows leakage current between turn.
When the shorted turn occur, the total ampere-turns produced by the rotor are reduced, since the
effective number of turns are reduced by the number of turn shorted. The result is an increase in the
required field current in the rotor to maintain the same load point and an increase in rotor winding
temperature.At the location of the short, there is also a high probability of localized heating of the copper
winding and arcing damage to the insulation between the turns. This type of damage can propagate and
worsen the fault such that more turns are affected or the ground-wall insulation becomes damaged and a
rotor winding ground occurs.
Although shorted turn maybe exist in a rotor, in many cases the rotor will still run with out significant
effect on the operation of the generator. In addition short can occur anywhere in the rotor winding, but
they often found In the end winding under the retaining rings
There are number of factors which will influence the seriousness of any particular shorted turn-turn how
they will affect operation of the generator, these tend to show vibration on the rotor.
When a short on one pole of the rotor occurs, a condition of unequal heating in the rotor winding will exist
between poles, the unequal heating will cause bowing of the rotor and hence vibration

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1. RSO ( Recurrent Surge Oscillation)

Slip-rings
Test function
When rotor stand still all
rotor winding is
Ground wire mechanical force free,
but during rotor spinning
all of rotor winding parts
RSO 220 Vac was forced out by
centrifugal force. Minor
insulation fail ( inter turn
Oscilloscope or turn to ground short)
may not identified when rotor standstill due to rotor winding insulation is free from mechanical force, this
test is very sensitive to mechanical force change.
RSO is useful to identified short inter turn on the rotor winding when rotor standstill or rotor running
without excitation
RSG inspection when rotor standstill RSG inspection when rotor spin 2500 RPM
Separate graph Joining graph Separate graph Joining graph

2. AC Impedance
This test is designed to determine the existences
AC Impedance Test
25.00
of shorted turn in the DC excitation field winding.
Z (Impedance)
Current
In round rotor, the individual windings are for all
20.00 practical purpose inaccessible, unless the
Z = V/I (Ohm)
Impedance Z = V / I
15.00 retaining rings are removed,

The Generator Field AC Impedance Test is
10.00
performed on Field to determine the winding
5.00 impedance at various voltage. Under some
-
circumstances it is possible to detect the presence
110.10
130.20
150.50
170.20
190.80
209.00
of shorted turn or changes in the number of

30.50
50.10
70.40
90.40
shorted turn in the winding by changes in

Test Voltage (a.c)
impedance at various test voltage when compared
to data taken previously if available.
Gradual change of impedance by change of voltage should be not more then 10 % , ref: NEMA MG1 /
IEEE Std 62

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3. ON LINE ROTOR INSPECTIONS
a. NTRODUCTION
Generator rotor thermal sensitivity is a phenomenon found on the generator rotor causing change in
vibration as the field The most likely problem with operation in the presence of shorted field windings is
excessive vibration.
Vibration in two pole rotors occurs due to uneven heating of the rotor forging. When turn shorts cause an
unequal distribution of active turns between poles, the amount of heat (I2R losses) between poles is also
unequal. This unequal heating will cause the rotor to bow and thereby introduce vibration. The coil
location of turn shorts is the key to determining if the rotor will experience vibration problems. In general,
unequal turn distribution in smaller coils will have a greater effect whereas unequal turn distribution in the
larger coils will have a lesser effect. For instance, one could expect vibration problems with only 5%
shorted turns in the # 1 coil of one pole of a seven coil rotor where no vibration problems would be
expected if the same percentage of turn shorts were present in the # 6 or # 7 coils.
One telltale sign of shorted turn induced vibration is the variation of vibration magnitude on increase in
load. Increased field current increases differential heating on the rotor forging, increasing bowing and
subsequent vibration. Some machines are observed to show the opposite effect. That is, the rotor
vibration decreases with increase in load. When this is the case, it is clearly the effect of compensation
balancing that has been done to offset shorted turn induced vibration levels at load.
In the past two decades, the use of on-line testing of generator rotor windings has surged. The benefit of
on-line testing has been recognized throughout the power generation industry and the installation of
airgap flux probe monitoring equipment has become almost standard procedure for utilities and OEM‟s.
Online testing for field winding shorted turns gives operators positive answers that can be used in trouble
shooting generator operational problems and helps determine whether rotor rewinding is required.
.
Prior to the widespread use of on-line air-gap flux probe testing, balancing programs would be performed
to compensate for shorted turn induced vibrations. If the results of the vibration testing indicated that
static weights were required at the pole centerline, it could be suspected that shorted turns were the
problem. As an example, one recently analyzed rotor was found to have shorts in the #1 coil of one pole
and the #2 coil of the opposite pole. Upon removal, the rotor was found to have two sets of balance
weights in place. One set on each pole had been placed to compensate for the shorted turn induced. The
balancing weights were placed to compensate for rotor bowing at full load, but actually throw the balance
off at lower loads when rotor bowing is not as great.

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b. ON LINE ROTOR SHORT DETECTION
Flux Probe installed in the stator
New shorted-turn detection technology has been

developed which can identify the coils with
shorted turns and the number of shorted turns in
the effected coils. The test data can be obtained
while the generator is at speed and normal
operating load conditions. With this information,
rational corrective action maintenance decisions
can easily be made. No special off-line test set-
up is required. (Impedance tests or stator short-
circuit tests ) Obtaining a baseline set of test
data before a critical shorted-turn condition
develops enhances the sensitivity of the
detection system.
The new technology uses a simple permanently mounted air-gap flux probe positioned on a stator
wedge. The probe is sensitive to changes in radial flux density magnitudes as the rotor surface passes
by. This waveform is the time rate of change of the radial air-gap flux density waveform. Thus, it greatly
amplifies minute variations in the slopes. Analyses of the flux probe waveforms can detect critical
shorted turn conditions.

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How it Works .
Step One
shorted turn detection/analysis system measures flux-density changes in the stator air gap. The flux
density reversals at each rotor slot are recorded at multiple loading conditions for later analysis. The flux
density at each slot, being a function of the number of active turns, is compared with its opposing pole
slot to determine the number of inactive or "shorted" turns.
Figure 1 shows the cross section of a 2-pole rotor and defines the stationary flux probe location. Figure
2 is a digitized waveform from a flux probe recorded during no-load conditions. The nomenclature of the
rotor and the associated waveform are identified.
Fig. 1 Fig. 2
Figure 1 - Field Nomenclature & Stationary Search Coil - 6 coils per pole
Figure 2 - Sample no-load data with field nomenclature - 6 coils per pole
Note that the voltage spikes are directly associated with the field slots. The flux probe (sensitive to radial
flux variations) provides voltage reversals at the centerline of the slots (labeled) and the centerline of the
teeth. These voltage spike magnitudes are a function of the active turns in the slots (slot leakage flux)
plus a distortion factor due to the air-gap flux density waveform. The success of the detection system
requires separating the slot leakage flux data from the distortion factors.
Step two
Figure 3 is test data from another generator taken
while the generator was at no load (open circuit
condition). Note the air-gap flux density waveform
passes through zero at the quadrature axis (90
degrees from the pole axis). The flux density
waveform can be obtained by integrating the flux
probe waveform. In the following displays the flux
density waveform has been inverted to minimize
overriding the pertinent search coil data (slot data
preceding the poles).
Figure 3 - Open Circuit (No-Load) Data

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Fig 4 – Low Intermediate Load Shorted Figure 5 - High Intermediate Load Shorted
Turns - Pole B Coil # 6 Turns - Pole A Coil #4
Test and analyses of waveforms when the generator is under load, show that the distortion factors,
mentioned above, are minimal where the air-gap flux density crosses through zero (zero crossing). It
has been shown that the zero crossing traverses from the quadrature axis towards the #1 coil slots
leading the poles as load is increased. Figures 4 and 5 show test data from the same unit displayed in
Figure 3. Note that the zero-crossings in Figures 3, 4 and 5 shift from the quadrature axis to near the
6th and 4th coil slots, respectively. This phenomenon is due to power angle shifts with load. Thus, by
taking roughly 5 sets of test data from zero load to full load at unity power factor, excellent shorted-turn
detection sensitivity can be obtained at all the coil slots preceding the poles. This machine suffers
shorted-turns in coil # 6 on one pole and coil #4 on the other pole. As can be seen in the figures, these
shorted turns are defined best at the loads where the air-gap flux density zero-crossing is aligned with
these slots.
Step Three
Using digital data, a computer program can invert the slot voltage spikes "Y" values of one pole and
align them with the data from the other pole for a direct comparison. Figures 6 and 7 are examples of
computer analysis displays of the base data in Figure 4 - Low Intermediate Load. With this data in digital
form, the computer can also calculate voltage spike amplitudes and/or areas for use to estimate the
number of shorted turns in the effected coil. Two turn shorts out of six turns in coil #6 pole B were
identified at this load. Without distortion effects, two turn shorts equate to a 33.3% smaller voltage spike.
The actual test data produced a 26% and 30% reduction using voltage spike amplitudes and area
ratios, respectively. Partial shorted turns can not exist; therefore, engineering judgement suggests that
there are two shorted turns.
Figure 6 - Lead Slots Data Comparison Figure 7 – Zoomed Data of Coils

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Figure 8 - Signature Analysis (25% Load) Figure 9 - Signature Analysis (70% Load)
Figures 8 and 9 are graphs of quantitative voltage spike amplitudes of all the coils for the generator
loads in Figure 4 and Figure 5 respectively. These type graphs for each load are signatures of the
winding condition when the data were taken. New test data, taken at the same loads, can be
compared to this data to improve the overall sensitivity for detecting shorted turns. For example, if
both pole A and B coils #6 had an identical number of shorted turns (2) during a retest, these original
graphs would help identify the condition.
Figure 10 shows an animation of real generator data
collected from no-load to a full load condition. The figure
is displaying overlays of the two poles' leading slots
signal, along with the location of the flux density zero-
crossing. Notice how the shorted-turn in coil #5-pole A is
visible when the flux density zero-crossing is near that
coil, but disappears when the flux density zero-crossing
moves away from the coil. This illustrates the need to
collect a series of load points designed to move the flux
density zero-crossing from the quadrature axis to the #1
leading coil slot in order to pick up potential shorted-turns
in each of the rotor coils.
Figure 10 - Leading slots overlay

Temporary Probes
this have described a simple air-gap flux probe
assembly, testing, and analysis program which
will significantly improve your ability to
understand your generator performance
variations. The probe described must be
assembled while the rotor is removed from the
stator core. There may be cases where critical
shorted-turn conditions are experienced before
a planned outage. On many generators, it is
possible to assemble a temporary probe as
shown in the figure below. The data from this
probe will provide the same definitive test results, thus allowing you to determine whether corrective
action should be performed at the next outage.

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Diminished Capacity
Excitation systems for generator fields have a certain amount of excess capacity. However, fields with
numerous shorted turns can sometimes require reducing full load values of MW‟s and/or MVAR‟s. In the
cases that we have observed that require load reduction, shorted turn indications are on the order of 5-
10% or greater. Machines in this category are candidates for a rotor rewind at the earliest opportunity.
Increased Field Current

The output of a generator is a direct function of the amp-turns values of the rotating field. Any reduction in
the number of active turns in a field will require a corresponding increase in the excitation current in order
to maintain the amp-turn value. These increases in field current are a direct cost to the power producer.
Likewise, increases in field current result in higher hot spot temperatures in the field winding.
The increase in hot spot temperature accelerates the breakdown of insulation systems and increases the
effect of temperature related deformation of the windings.
c. The Causes of Shorted Turns
1. End Strap Elongation

End strap
elongation is the
result of frictional
forces between the
top turn end straps
and the retaining
ring insulation. If
the coefficient of
friction between
the retaining ring
insulation and top
turns is too great,
the expansion of the retaining ring due to centrifugal force will stretch the top turns beyond their yield
point.
At the start of the next Start/Stop cycle, the end strap(s) are slightly longer that they were at the start of
the previous cycle. After a number of cycles, the end straps have expanded to a point where they come
into contact with turns of an adjacent coil. Higher rotor vibration will normally occur and a jump in field
current will be experienced. On a seven-coil field, for example, two coils shorted out will require a 14%
increase in field current. End strap elongation problems can be mitigated by careful selection of insulating
materials and/or the application of intermediate layers of material that decrease the coefficient of friction.
2. Body Copper Foreshortening/Soft Copper
Body copper foreshortening is a result of the body copper being unable to expand freely along the length
of the rotor. In general, the copper conductors will expand faster and further than the rotor body. Blocking
arrangements and friction due to centrifugal forces tend to act against the free expansion of the body
copper. When the copper cannot fully expand, it tends to compress within the slot in the rotor body.
When these compression forces exceed the allowable material stress, the material deforms within the
slot. The end result is a shorter length of copper at the end of the Start/Stop cycle. After a number of

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cycles, the deformed copper can cause cracking in the turn insulation within the body or cause serious
misalignment of the end turns. If end turn misalignment is severe enough, the stacked turns of the
affected coil cannot support its own weight under centrifugal force. Most copper foreshortening problems
are the result
of using
materials
with
insufficient
yield
strengths.
3. Blocking Problems
Although not as
prevalent as other turn
short causes, end-
winding blocking
problems have been
the cause of a number
of shorted rotor
winding conditions that
we have observed over
the years. The purpose
of end-winding
blocking is to maintain
the alignment of the end-windings during operation. The cases missing blocks or blocks that have moved
out of position as shown in Fig. 6. Most blocking arrangements have been developed and/or refined by
manufacturers through experience with past problems. Service organizations should pay close attention
to the manufacturers recommendations for blocking installation during rewinding.
Endwinding Blocking loose GE Generator 49.5 MVA / 11500V / 3000 RPM

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Bowing caused by uneven blocking
Distance Endwinding Block Fitting
The distance blocks that provide the spacing in the generator field end windings must be spaced and fit
properly. Uneven spacing and/or fitting can cause non-uniform forces to be transmitted into the field
forging through the retaining rings or centering rings and, like all the other possible causes of thermal
sensitivity, make the rotor bow and change dynamic characteristics.
(See Figure.) Uneven distance block fitting will cause reversible vibration
FOR DETAIL SEE THERMAL SENSITIVTY TEST

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F. VISUAL INSPECTION
F.1. STATOR
GE GENERATOR 237 MVA / 15.5 KV / 3000 RPM

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1. Frame and frame extension
Important information on the general condition of the machine may be obtained from a general view of
the bore area and frame.
Inspection to be obtained for instance :
Excessive discoloration of paint of the paint on the casing, frame and bore indicate a probable
case of overheating
Presence of large amount of oil or dust
Excessive amount of iron powder mixed with oil and dust or found alone in the bore area tend to
indicate a loose of core
2. HV Bushing and Flexible Bus Connection

HV Bushing sometimes have passages built inside them to allow the flow of air or hydrogen for cooling
purpose. It is important that the vent are inspected to see if they are uncloged, cracking, dust deposit
loose part, its could be arise from any sudden load change, vibration over long time period, overheating
of the lead,
Crack,
Loose parts,
Presence of large amount of oil or dust
Damaged of sealed bushing, clogged vent
Crack can occur on the flexible bar

connection due to vibration.

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3. End Winding ,Connection Rings and support

Inspection Coil Cleanliness
Contamination causes degradation of the insulation by providing a medium for currents to flow on the
surface of the coil insulation. The result in tracking and reduction of the insulation properties.
The presence of large amounts of dust and oil or dust-oil mixture and carbon dust on the coils.
4. Blocking condition, Ties between coils tight
The blocking consist of the material used to separate

the side of the coils at the end-winding and between
end-winding connection.
Blocking coils are used to determine the clearance

between the coil side at the end region, to eliminate
mechanical stresses arising coil movement, that will be
resulting coil touching each other at the end-winding.
Coils will rub each other at 2 x f during machine in the

operation, and during starting, sudden change of load
(or external short-circuit) will be create large movement of the coils end, and combined with different
temperature relate expansion of coils are strongly reduced coil insulation properties.

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5. Surge ring insulation condition, Ties to surge rings tight ?,
The end-winding of electric machine are subject to substantial movement during sudden change load,
vibration on normal operation. To minimize of end-winding movement the side coils are tied to a circular
rings are commonly called : “surge-rings or support rings “.
In large machine surge-rings are normally made of steel, and the steel are covered with several layer o
insulation. Te purpose of insulation on surge-rings is to minimize of a ground fault to the rings. The surge
rings insulation can deteriorate due to electrostatic discharge from the coil, is appear as electrical
tracking and/or burnlike marks on the insulation.
6. Surge ring support assembly
Sludge and white powder on

the support and ties are
indicate high vibration
The surge rings restrain the
movement of the oils by
distributing the forces by one
coil onto other coils, and by
transmitting them to the
frame of the machine. In
order to accomplished that
the surge rings are
supported by support assembly.
In a simple cases they are designed a steel arms welded or bolted
to the frame.
The sign of lose parts, bolts and/r nuts
greasing bolts
cracked or loose of welding

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7. Core compression nuts and bolts
In large machine he stator

Melted key bolts and tooth area due to over flux.
core is almost always
compressed by “ core-
compression bolt “. These
are torqued to values
specified by the
manufacturer during the
assembly.
Normally compression to
around 150 psi, if part of the initial compression within the core is lost. The looseness of core is indicate
by movement of nuts and bolts on the core compression against the compression plate.
8. Out going cable support
Cable support is designed to out going lead cable from generator stator winding to termination, loose on
the clamps support can occur due to vibration during machine in operation, loose support can caused
crack on the termination and lead cable insulation.
Brownish color is indicate overheating and white powder is indicate excessive vibration .
9. Insulation Condition
Thermoplastic, resin / epoxy polyester binder, insulation system when exposed temperature will become
dry and brittle, the exposed temperature may arise from overload condition, poor cooling, damage core
section, negative sequence current due to unbalance, etc.
Overload condition will show-up as an external discoloration of the insulation, brittle winding will show
powder accumulation arising from the movement of the shrunken coil within the slot.
The insulation degradation will be rapid growth-up if partial discharge activity are developed.
The sign of discoloration
The sign of greasing

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Deterioration of Stator Coil
Thermal Operating Insulation Condition

Temperature
Electrical Surge voltage
Mechanical Electromagnetic
vibration
Damage of Stator Generating the VOIDS

Coil Insulation
Partial Discharge
10. Tape separation (girth-cracking ?
A problem common to machines with thermoplastic insulation

is that the normal thermal cycling is causes coil movement in
the slot, tend to generate crack within the ground wall
insulation.
A tape separation is a separation of tape covering the wall

insulation of the coil due to axial expansion and contraction of
the conductors and the opposing forces of the slot applied to
the wall insulation.
In some cases only the armor tape is separated, in other cases the mica-tape comprising the ground-wall
insulation is also affected , when this occur a few layer may be affected and the whole tape will move
creating “ a neck” in the coil.
11. Insulation Galling/necking beyond slot
Necking is a lack of insulation which has been cracked and

separated causes by thermo cycling in thermoplastic
insulation.
Necking is always a sign of a weak point in the groundwall
insulation. Some of the coils are made in the slot portion with
a slot wrapper, while at the end-winding region a tape is
used.
The interface between the two region close to the end of
core is called a “ scarf joint. “.

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Scarf joint represent a weak mechanical point in the structure of the coil, tending to separate under
thermal stresses .
12. Insulation bulging into Air Duct
Bulging of the insulation right outside the

slot and in the cooling vents is an indication
of a soft spot , tape separation, girth cracks
or asphalt migration.
The sign of the separation, girth and
necking in the wall insulation :
The lesser extent in the cooling
vents
13. Endwinding blocking coil and ties

The blocking consist of the material used to
separate the side of the coils at the end-winding and
between end-winding connection.
Blocking coils are used to determine the clearance
between the coil side at the end region, to eliminate
mechanical stresses arising coil movement, that will
be resulting coil touching each other at the end-
winding.Coils will rub each other at 2 x f during
machine in the operation, and during starting,
sudden change of load (or external short-circuit) will
be create large movement of the coils end, and
combined with different temperature relate
expansion of coils are strongly reduced coil insulation properties.
Blocking coils are almost made from solid insulation materials (such as textolite, felt, etc) which is soaked
in resin.
Blocking coil is always held in place with ties. Often solid separator tend to loose after long period of
operation, in severe cases it will fall from the winding.
The presence of large amounts of dust and oil or dust-oil mixture and carbon dust blocking
Sign of loose blocking
Sign of too dry ties, loose of ties, broken ties
Powder, abrasion sign on coils, and missing of blocking pieces

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14. Corona activity
Corona is define as the ionization of gas when exposed to an intense electric field the discharge have a
wide range of frequencies [ 40 kHz to 100 MHz ].
Corona activity in the rotating machine :
Corona at end winding ( End-
winding Discharge )
Corona at inside of the insulation
( Internal Discharge )
Corona at ground-wall insulation
( Slot Discharge )
Corona at overhang of winding (
Surface Discharge )
Corona activities on the endwinding
Endoscopic Inspection
Corona activities at endwinding can inpected with naked eyes, but corona at wall insulation caused by
slot discharge only can inspected by measurement and indoscopic method.
Top Bar
Bottom Bar
Partial discharge
Magnetic core
15. RTD and TC
Resistance Temperature Detector ( RTD ) and or Thermocouple ( TC ) are mainly found in the winding,
cooling gas flow path, cooling water paths and bearings.
Winding temperature detector normally of RTD type are located between the coils in inaccessible
area.
However wiring to and from these devices is partially accessible for visual inspection, its should be tight
and secured along its path to the coils, frame and termination casing. If winding temperature detector are
faulty, they can be replaced during a major inspection. the damage of RTD are left in place with their
wires are disconnected or removed and the new RTD are taped and glued to the coils as close to the
damaged of RTD as possible, in generally they will be located in the end-winding.
The presence loose, broken for connection, path, cable,

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16. Fan Baffle support studs
Most of large machine (gas and or air cooled) are provide an baffle to directing of the cooling from and to
the fan. Fan baffle are supported stud is mounted on the tip of the core-compression finger with spaced
studs are placed around the bore
The fan baffle are subjected to continuous of vibration, stud and bolts should be inspected for stresses-
fatigue cracks, if broken during machine in operation they will probably causes extensive damage to the
windings or rotating elements particularly the fan blade.
The presence of red oxide
the presence of loose, broken cracks
17. End Winding Support Hardware
In large synchronous machine, the end winding connection normally supported by support hardware.
The presence of powder deposit causes abrasion
The presence of loose, broken cracks
18. Circumferential Bus Insulation
Circumferential buses is circular shape phase connection are normally

separated from the rest of the winding by relatively electric clearance
and commonly insulated and they are supported by a structure mostly
made of steel bolted or welded to the frame.
The circumferential busses are subjected to movement by vibration,
tend to separate of their insulation and together with the contaminant
they will be produced electrical tracking and will result in phase to
phase failure. Occasionally low megger reading due to the fault this
insulation.
The insulation failure will rapid growth causes the circumferential
busses are located close to rotor fan.
The presence of powder deposit causes abrasion
The presence of loose, broken cracks of insulation
19. Bar Bottomed in Slot

Is bar seated tightly on the bottom of the slots. Coils not bottomed
in slots indicate a loose-coil condition with all the problems and
consequences coils movement within the slot, thus the semi
conductive and wall insulation will be damaged.
A mirror or AV camera permits inspection around the end-winding
and observation of the end core area and the bottom of coils.
The presence coils movement at axial direction
coils still in good position in the bottom slots

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20. Core inspection

Core condition
All parts in
generator are
exposed to
continual
vibration,
temperature
change and
other
mechanical stresses. They may become loose, fractured or broken. Its important to search for these
abnormalities during the inspection before they develop into major troubles. In particularly all components
of the core assembly are subjected to mechanical stresses due to sudden load change, such as during
loss load, short-circuit, closing out of synchronism. In general condition core can be inspected with visual,
beside inspection with a measurement ( EL CID, Loop).

The presence of iron oxide, can result from core loose and wedges
Iron deposit in the bore, found iron deposit indicate loose core
21. Lamination Bent or Broken in the Bore ?

Core lamination are often damaged
during removal rotor, when this occurs
its become partially short-circuit, if left
on this condition they may become
reach excessive temperature during
operation, and will resulting damage to
the insulation between of lamination‟
If found short-circuit in the lamination
or group of lamination, the top
lamination should be separated and
Main defects of Stator Core and Inspection impregnated with resin or epoxy.
Its most important to identify
Dent lamination that are broken or in the
Damaged to the Stator bent, any broken of pieces lamination
Scratches Core Circulating will got loose and most probably will
Current damage the insulation of coils
Loosenes Damaged to Insulating
s Film
Inspection to be obtained for
instance :
Melting Overheating
The presence of iron oxide,
can result from core loose and
Precision Inspection wedges
using EL CID
The presence of dent, bent

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and broken may causes by rotor removal or inserting foreign material during machine operation.
Core Looseness
Core looseness usually will occur at the inside diameter near the ends of the core. However, it is possible
for looseness to be general and/or exist on the core outside diameter. If looseness is suspected, degree
of looseness can be evaluated by carefully inserting a knife blade between punchings at several
locations. If a 10-mil (1 mil = 0.0254 mm) blade penetrates more than round a quarter of an inch (6mm),
the core may be not sufficiently tight.
EXTREAME CARE SHOULD BE TAKEN NOT TO BREAK THE BLADE, LEAVING A PIECE IN THE
LAMINATIONS !
Looseness may be accompanied by dust generation, punching and spacer movement, or small pieces of
punchings flaking or cracking off.
22. Slot and Wedges mapping

Wedges Condition
Wedge inspection will be applied after rewedging its will be upgrade from the original (class B random
glass mat? ) to high pressure laminate glass cloth impregnated with high temperature epoxy resin NEMA
G11, include radial spring and fillers G-11
a. Wedge Function and Tightening Test by manual tapping

The wedge is one of the main elements controlling the tightness of the coils in the slots, maintain the
positive pressure on the coils reduces their movement within the slots to minimizing loss of
semiconducting coating and wall insulation.
Slot electromagnetic forces are high and deterioration is common and can be severe. The slot portion of
the stator winding is probably the most critical and difficult area of a generator to properly inspect. Most of
the important areas of interest are enclosed behind the wedges and the core iron.
The common way to inspect wedge condition is to tape on one side of the wedge with a small hammer
and sense the amount of movement with the other hand touching the other side of the wedge. Given the
response the wedge condition can be classified either as tight, loose or hollow.
Measurement wedge
Body wedge
End wedge
Radial springs Loose Wedge

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b. Acceptance criteria
Following are threshold criteria of unsatisfactory wedge standard reference, Some literature and
manufacturer have a different criteria for unsatisfactory threshold of wedge to decision re-wedge , repair
or continues to operation. taken from IEEE Power Engineering Series and Toshiba Corporation TIL ECS
– 990506P.
Toshiba Corporation TIL ECS – 990506P for Preventive Maintenance of 125 and 250 MVA Turbine
Generator, recommend a threshold criteria as follow:
If there are 2 (two) consecutive looseness wedge in the same slot or if the percentage of
nonconsecutive looseness wedge is less than 30% from total number of wedges in a same slot,
the looseness wedges are applied the epoxy resin by brush between stator core and stator bar
wedge
If there are 3 (three) or more consecutive looseness wedges in a same slot, or if the percentage
of nonconsecutive looseness wedges reached 30% or more of total number of wedges in a same
slot, the all wedges in the slot shall be disassembled and replaced with new ones.
Note: Application of epoxy resin is only temporary countermeasure for the looseness.
IEEE Power Engineering Series recommend a threshold criteria as follow:

25% or more of loose or hollow from total number of wedge, its required to re-wedge.
15 - 20% of loose or hollow from total number of wedge, its require to repair
15 – 20% of loose or hollow wedge are concentrated in 1 (one) row will require re-wedging in that
slot
Filler Slipping Out at End
Filler slip out on Gen GE 25 MVA Filler slip out and burn mark on the stator winding
MITSUBISHI 125 MVA.
Another indication of loose coils at least radial direction is movement out of the bottom and or top slot
filler .
Normally the filler are driven back (if possible) 0r broken at the end of core. In both cases they are
secured with resin-epoxy or RTV .
As with the movement of end wedge large number of fillers slipping out of core by several inches may
indicate a loose winding condition. However filler movement can also be result of elongation and
contraction of the coils due to thermal cycles, even in tight coils.
The presence of loose, slipping out at end portion of core

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c. New Stator Wedging System

Perhaps no other generator component has been through more design variations over the years than the
stator wedging systems. At this time, however, most suppliers use either a flat wedge (with radial spring if
space is available), see figure, Provided that the new wedging system is correctly installed, and provided
that the bars are down in contact with the bottom of the slot, the rewedged winding should not need
further wedge repair for many years.
Side Filler Strips are strips of semi-conductive material that fits between the stator bar and the slot wall.
Material for this application is semi-conductive to ensure a secure contact between the outer corona
protection of the copper bars and the walls of the slot. This material must also be strong mechanically to
provide a tight lateral fit for the copper bar.
Top Ripple
Side Ripple

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d. Stator Wedges Design
Over the years, the industry has developed several different wedge design variations based on the type
of generator manufactured. We can make a complete line of wedge designs based on our experience
producing wedges for nearly every type and manufacturer of generators. A sampling of common wedge
designs would include the following:
It should be noted that We does not possess nor utilize any OEM drawings in order to produce wedges
for our customers. We reverse engineer wedges and various insulating components based on samples
provided by the customers as well as our years of experience manufacturing these components.

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e. Material Alternatives
Low Shrink Black Canvas - Used in the majority of large and medium sized GE generators. Exceed
the requirements of GE Spec. A50A341A. This material is the primary material used by Our Partner
Company in U.S for re-wedges of GE generators.
Post Bake Black Canvas – Used in smaller gas turbine generator designs, but does not meet the
much more demanding specifications for Low Shrink Black Canvas per GE Spec. A50A341A. Note that
Low Shrink Black Canvas and Post Bake Black Canvas are nearly identical in appearance, but Post Back
Black Canvas is dramatically lower in cost and dramatically different in performance.
Glass Epoxy Laminates (NEMA Grades G-10 & G-11) - Used in Westinghouse and ABB
generators. Also used in some GE generators as a replacement for Low Shrink Black Canvas.
Glass Polyester Laminates (NEMA Grades GPO-1,-2,-3) - Used in Allis Chalmers and Electric
Machinery generators as well as several different models of hydro generators.
Top Filler Strips
Description
Top Filler Strips are strips of dielectric material that fit snugly between the stator winding bars and the
stator wedges. Their primary purpose is to fill space between the bar and the wedge and ensure a tight
radial fit. Top Filler Strips must have a slick surface for ease of strip placement and excellent mechanical
strength.
There are several materials that meet the requirements of the Top Filler application. The most commonly
ordered materials are NEMA Grades G-10, G-11, CE and LE. Many also use Top Ripple Springs, which
provide added radial pressure on the stator wedge. We stocks each of these materials in the following
thicknesses:
Material Thickness Range

NEMA Grade G-10 0.010” – 0.250”
NEMA Grade G-11 0.010” – 0.250”
NEMA Grade L - E 0.020”- 0.250”
NEMA Grade C – E 0.020”-0.250”
Top Ripple Spring 0.8mm and 0.9mm

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Unless the repair crew is trying to maintain a Class B insulation system, the most cost effective material
for this application is NEMA Grade CE. For Class F insulation systems, NEMA Grade G-11 is a common
choice. Top Ripple Springs are rated Class F and are used in either Class B or Class F insulation
systems.
Side Filler Strips
Description
Side Filler Strips are strips of semi-conductive material that fits between the stator bar and the slot wall.
Material for this application is semi-conductive to ensure a secure contact between the outer corona
protection of the copper bars and the walls of the slot. This material must also be strong mechanically to
provide a tight lateral fit for the copper bar.
There are a wide variety of semi-conductive materials on the market. Each of the major U.S. laminate
manufacturers, as well as several European laminate manufacturers, have products to fit this application
for the generator repair industry. We stocks the following materials for this application
A random glass mat laminate with polyester resin with semi-

conductive properties.
This material is the least expensive material on the market
C-109 - and has gained market acceptance after being one of the first
materials introduced for the application.
Thickness Range: .010”-.250”

A woven glass reinforced glass epoxy laminate with semi-
conductive properties. It has a high temperature (Glass F)
G - 11 SC - epoxy resin system coupled with the excellent mechanical
strength of a woven glass laminate.
Thickness Range: .010”- .250”
A woven glass phenolic laminate with semi-conductive

properties. A high temperature Class F resin system provides
excellent thermal properties along with very good mechanical
G – 3 SC -
properties at a reasonable cost.
Thickness Range: .015” - .250”

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A woven glass epoxy laminate with semi-conductive

properties. A high temperature Class F resin system provides
excellent thermal properties along with very good mechanical
properties. GGBE-R offers outstanding consistency in terms of
Pregnit GGBE-R
surface resistivity.
Semi-conductive fleece are non-woven materials with high

Fleece flexibility and longitudinal strength with relatively small
material thickness. They exhibit high abrasion resistance
10 EWR 02 AA during operation of the machine, as well as trouble free
06 ELR 14 AA processing by cutting, folding and die-cutting.
03 EFR 13 AA
This material has a formed wave pattern that is situated on a

45-degree angle to the corner of the sheet. The wave pattern
helps provide a tight lateral fit for the copper bar when
Side Ripple Spring - pressed into place.
Thickness Range: .3mm, .5mm, .8mm, .65mm, .94mm,

1.0mm
23. Core dampen bars or frame vibration
Frame vibration is also excited by unbalanced magnetic pull and by any vibration produced in the core.
There are known cases of vibration resonance occurring on the frame as a result of the frame having a
resonant frequency near line or twice line frequency. Resonant frequencies may be corrected by either
adding mass to the frame to bring the natural frequency down, or by stiffening the frame to drive the
natural frequency higher; the object being to move the frame natural frequency away from the exciting
frequencies by at least 10%.
Severe damage to the frame can occur by initiating cracks in the frame welds or in the frame members
themselves. Residual damage from the high vibrations associated with frame vibration is likely to be
transmitted to other components of the generator if the situation becomes severe.
Good core-to-frame coupling is required to ensure that the core and the frame move together. There is
evidence of numerous cases where core frames became “uncoupled” from the core and impacting
damage found at the core to key bar interface. Such vibrations were corrected in past by spring mounting
the core to the frame or installing a damping arrangement to “de-tune” the vibration modes.
Monitoring of frame vibrations can also be done with accelerometers mounted on the key bars, frame
ribs, or casing structure in strategic locations to determine the magnitude and phase of both radial and
tangential vibration modes. (Fig. below).

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Tangential frame vibration bars, identify Excessive discoloration of paint of the paint on the
casing, frame and bore indicate a probable case of overheating, crack, bent etc.
Radial frame vibration bars, identify

Excessive discoloration of paint of the paint
on the casing, frame and bore indicate a
probable case of overheating, crack, bent etc

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F.2 ROTOR INSPECTION

1 ROTOR TURBO GENERATOR
1. Rotor Cleanliness
A rotor exhibiting numerous deposits of copper
powder indicate excessive movement of the DC
field coils, the excessive copper dust should alert
the inspector to possibility of the existence or the
development of shorted turn and / or ground fault.
Copper dust, iron dust, or any other telltale material
my concealed in a mixture of oil and dirt, can mask
cracks on the surface of critical components such
as wedges, fan hub and blades, retaining rings, bar
connection, etc. Heavy dust deposit affect to the
flow of the cooling gas or air, in affect de-rating the
machine.
The presence deposit copper or/and iron
powder
cracks on the surface of wedges, blade, retaining ring etc
Inspection on endwinding to verify copper powder deposit
2. Rotor Wedge Inspection

Hot spot found on the vent
holes of rotor wedges
During unbalanced load or

supply condition, motoring serve
or generation with the field off
(induction mode operation),
inspection of the rotor should
always include inspection of the
wedge-ring contact area, as well

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as between the wedges themselves and between wedge to the rotor body, its important to note that any
sign of burning should be carefully investigation.
During systems oscillation or other type of abnormal operation, alternating current are established in the
body of the rotor.
These current tend to flow along to the rotor body (pole and teeth) , along the wedges and in the end
bells (retaining rings).
When bridging high resistance contact area, these current may give rise to very localized pitting of the
metal. These high-resistance area mainly found in the contact surface between the wedge and the slot,
between different wedge, and between wedge and retaining ring.
Pitting sign found on the rotor wedge due to alternating current are established in the body rotor
End wedge migration, touch to retaining rings can caused

flash over and overheating
End wedge
migration to RR
3. Retaining Rings Visual Appearance

The retaining ring are the
most critical component in
the rotor and normally the
most highly stressed rotor
component. These rings
are critical in the sense
that their mechanical
failure causes by SCC
(stresses corrosion crack),
mostly 18-5 type of ring
(18% manganese-5%
chromium alloy),

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The visual inspection on the retaining ring can be made as nondestructive examination (NDE) of the
several type available such as:
eddy current
acoustic
die penetrant
If the visual inspection of the surface reveals oxidation traces: - pitting, or other warning anomalies,
inspection of the inner side of the retaining rings might be advisable.
4. Endwinding blocking inspection.
End winding blocking arrangement
The endwinding blocking must support the winding to prevent permanent distortion, yet also allow for
thermal expansion. (See Figure.) The blocking materials that are currently utilized are epoxy glass
laminates. It is important to employ a service-proven blocking pattern that is compatible with the specific
endwinding geometry being used, since it is the blocking pattern which allows for thermal expansion
movement and ventilation. Also, special consideration must be given to the blocking and support of pole-
to-pole, coil-to-coil and terminal connectors. It should be noted that
asbestos was used extensively in older generation distance blocks and rotor insulation; maintenance/
repair processes must take this into account.
Some design features are added when high cyclic duty is anticipated. These include reliefs
in either the copper or body at the end of the coil slots to prevent armor damage, reliefs between the slot
armor ends, and the blocks just outside the body when rigid armors are utilized.
Loose winding block

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Some times centering is constructed with narrow space , hand touching and conventional camera is
inaccessible to inspect the endwinding blocking and other parts under retaining ring area. endoscopic
camera is require to inspection.
Endoscopic inspection under retaining rings
Tangential wedge which

support the interpolar
connection. CRACK
Rotor copper winding
interpolar connection.
Rotor winding inspection by using endoscopic camera when retaining ring in place

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5. Retaining rings removal inspection

When the rotor winding or other parts under retaining rings failure, detail inspection should be carried out
with retaining rings removal. to remove retaining rings should be done by an expert or supervising with
the appropriate equipment , Many people have attempted to do this kind of work with disastrous results
and I really mean disastrous
Setting rotor to body support
Check the gap C-clamp to RR
RR being removed
CRR heated by PWHT
PWHT logic control
CRR‟s was completely removed

RR in transportation

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ROTOR AREA INSPECTION
PT : Dye Penetrant Test, MT :

Magnetic Particle Test, UT :
Ultrasonic Test, VT : Visual
Test ( damage, rust,
discoloration), when retaining l
in place or removal / complete
rewinding.
NDT Inspection on the rotor, is designed to verify any anomalies on the retaining rings, centering
rings, rotor fans , journal shaft and bearings
Inspection on the retaining rings when the retaining rings removal

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Clean-up CRR‟s before NDT inspection before removal NDT inspection after CRR‟s
removal and NDT inspection removal
6. Rotor Forging and accessories NDT inspection

Rotor body was prepared in the dark room before MPI test.
MPI test entire rotor body, no anomalies was found Steel wedges NDT inspection

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Retaining rings inspection with-out removal Rotor fan inspection
Rotor fans ,centering rings and coupling bolts inspection
Journal shaft, bearing and oil baffle inspection
7. Degaussing / Demagnetizing
Magnetism in Machinery, account for many machinery failures, in particular the deterioration of bearings,
seals, geras, couplings and journal has been attributed to electrical currents in machinery. Often on
machinery groupings contain no components with electrical windings or intended magnetism, ie. No
motors, generators. Manufacturers of electrical equipment have recognized and protected against the
effects of electrical shaft currents, bearing insulation has been utilized for such purposes.
There are number of ways in which steel machinery parts can become magnetized. Placing a part in a
strong magnetic field can leave substantial residual magnetism. Mechanical shock and high stressing of
some materials can also initiate a residual field.

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Another that can creating residual magnetism is the passing of electrical current through the parts,
electrical system faults nearby heavy electrical currents such as rectified supplies and lightning,
electrostatic discharges, which are credited with causing bearing and seal pitting, the use of electrical
welding and heaters on pipes and other parts is common and if not used properly can induce residual
magnetism.
Demagnetizing on the HP/LP turbine, bearings, couplings, gears

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Magnetism in Machinery
Magnetism in machinery accounts for many previously unexplained machinery failures. In particular, the
deterioration of bearings, seals, gears, couplings and journals has been attributed to electrical currents in
machinery. Often, such trains or machinery groupings contain no components with electrical windings or
intended magnetism, i.e., no motors or generators.
Since the turn of the century, manufacturers of electrical equipment have recognized and protected
against the effects of electrical shaft currents. Bearing insulation has customarily been utilized for such
purposes.
Only since the mid-1970's has the need for protective measures on totally mechanical systems been fully
realized. The evolution of turbine and compressor systems towards high speeds and massive frames is
acknowledged as the cause for a new source of trouble from magnetic fields.
An electrical generator converts mechanical power to electrical power through magnetic fields. A
conventional generator rotor is essentially a magnet that is rotated in such a manner that its magnetic
field flux passes through coils of windings. Propitious placement of the coils in slots and other design
features result in the conversion of mechanical energy to electrical energy. This produces electrical
voltage and power in the windings that is then delivered to the electrical load or power system.
A turbine, compressor, or any other rotating machine that is magnetized behaves much the same way.
The magnetic steel parts provide a magnetic circuit, and are also electrically conducting so that voltages
are generated, producing localized eddy currents and circulating currents. These currents will be either
alternating or direct, and can spark or discharge across gaps and interfaces, producing sparking with
frosting, spark tracks, and, in the extreme, welding. They can cause increased temperatures and inflict or
initiate severe damage.
The generator action occurs as a result of relative movement between the magnet and the "conductors."
Hence, either the frame of a machine or the rotor can be magnetized, and the same action exists when
relative motion occurs between the rotating and stationary parts.
The magnetic field density in the air gap of assembled and operating motors and generators is designed
to be in the order of 7,000 to 9,000 gauss. These fields are capable of generating from watts to
megawatts of electrical power, depending upon the speed and size of the generator.
The field levels due to residual magnetism in turbomachinery occur not from design but from
manufacturing, testing, and environmental causes. They have been measured at the surface and in gaps
of disassembled parts of a machine at levels from 2 gauss to thousands of gauss. These increase
significantly in the assembled machine where the magnetic material provides a good closed path for the
magnetism and the air gaps between parts are reduced considerably. This combination can set up
conditions for generation of notable stray voltages and the circulation of damaging currents.
There are a number of ways in which steel machinery parts can become magnetized. Placing a part in a
strong magnetic field can leave substantial residual magnetism. Mechanical shock and high stressing of
some materials can also initiate a residual field.
Another method of creating residual magnetism is the passing of electrical current through the parts. In
increasing order of their effect, following are the known examples: Electric system faults; nearby heavy
electrical currents, such as rectified supplies and chemical processes; and lightning. Electrostatic
discharges, which are credited with causing bearing and seal pitting, can also be insidious sources in
magnetization of shafts.
The use of electrical welders and heaters on pipes and other parts is common and, if not used properly,
will induce residual magnetism.

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Items that have been subjected to magnetic particle inspection often retain residual magnetism because
of insufficient or improper demagnetizing following the test.
Components that have come in contact with magnetic chucks and magnetic bases often display multiple
adjacent poles of a residual field.
Field Measurement and Demagnetizing

Magnetic fields are measured with devices called gaussmeters. As the name implies, these meters
measure magnetic flux density in units of gauss. Most meters utilize a probe that works on the "Hall
Effect." This type of probe utilizes high frequency currents in its semiconductor chip to produce a
characteristic proportional to the magnetic field. Usually, only the very tip of the probe is field sensitive.
Fields that pass perpendicular to the face of the Hall Effect semiconductor are measured. The Hall Effect
probe performs expertly in measuring direct (DC) magnetic fields. Its accuracy, and the interpretation of
just what is being read if it is employed for measuring alternating (AC) fields, is uncertain and
questionable.
Reliable AC gauss or milligauss measurements are usually obtained employing separate circuitry in the
gaussmeter, and a different probe encompassing an AC fields sensor coil. It can be used on operating
machines or in environments containing alternating fields.
Magnetic fields are directional, being "North" at one end and "South" at the other. Hall Effect probes are
directionally sensitive. If the probe is flipped over, a reverse reading is indicated, consistent with sensing
either a North or South pole. With digital metering, the sign of the field is automatically indicated (+ or -).
Analog meters with a zero center scale will read to the left or right of zero. Keeping one side of the probe
(such as the side with the calibration number) always facing away from the object being measured and
calling it a North pole when the meter reads positive, establishes a convention for locating North and
South poles, and the orientation and path of the magnetism that is creating the poles.
This arbitrary choice for a North pole may be opposite from the established convention; however, it is
fully adequate in locating magnetic circuits and their magnetizing forces for purposes of degaussing.
Should agreement with established convention on polarity identification be important, the North pole side
of an identified reference magnet may be utilized for determining which outward-facing side of the Hall
Effect probe produces a positive magnetism reading, which should be labeled North.
A good gaussmeter has a calibration means to verify proper probe calibration, as well as a zeroing
adjustment. The zeroing procedure requires that the probe be temporarily inserted in a "zero gauss
chamber." These small chambers shield out stray fields, including the Earth's field, so that a true zero
field is realized. A typical Gaussmeter
Maximum Allowable Residual Magnetic Field Levels (As Measured in Open

Air)
Bearing components, including pads and retainers, journals,

2 gauss:
thrust disc, seals, gears and coupling teeth.
4 gauss: Bearing housings.
6 gauss: Mid-shaft and wheel areas, diaphragms, etc.
Components remote from minimum clearance areas, such as

10 gauss:
casings, pipings, etc.

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8. Schematic rotor and the areas most prone to be damaged by the “skin-currents”.
Schematic representation of a turbogenerator‟s rotor and the areas most prone to be damaged by
the “skin-currents” generated during inadvertent energization event.
Unexcited Operation („„Loss-of-Field‟‟ Condition)

Operation without field current is potentially dangerous and can occur under a number of
circumstances. The following are the most common two:
- Loss of field during operation. If for some reason the field current goes to zero while
the generator is connected to the system, the machine starts acting as an induction generator.
The rotor operates at a speed slightly higher than synchronous speed and slip-frequency currents
are developed.
These penetrate deep into the rotor body because they are of low frequency (this does not
represent the skin effect discussed in case, below). Severe arcing between rotor components and
heavy heating may result. The ends of the stator core also experience heating due to stray fluxes
in the end region, more severely than for operation at underexcited power factor. Protection is
commonly provided to prevent or minimize the duration of this mode of operation, by the so-called
loss-of-field relay.
- Inadvertent energization. If a generator is at rest and the main generator three-phase

circuit breaker is accidentally closed connecting it to the power system, the magnetic flux rotating
in the airgap (gasgap) of the machine at synchronous speed will induce large currents in the rotor.
The rotor then will tend to start rotating as an induction motor. The very high currents induced in
the rotor will tend to flow in its surface, in the forging, wedges and retaining rings. As the rotor
accelerates the currents will penetrate deeper and deeper.

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The maximum of damage occurs while the speed is low and the large currents concentrate in a
thin cross section around the surface of the rotor (due to the skin effect). The temperatures
generated by the large currents, flowing in a relatively small cross section of the rotor, create very
large temperature differentials and large mechanical stresses within the rotor. Areas most prone
to damage are at the ends of the circumferential flex slots. Other areas are the wedges and in
the body-mounted retaining rings, the area where the rings touch the forging and the end wedges
(see Figs. below)
Rotor damaged due to skin effect current resulting by high reverse power attack from GSU 150 kv
Transformer
Damaged on circumferential flex slot
Damaged on steel rotor and retaining ring

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The initial stator current supplied from the power system will also be very high, but the most vulnerable
part of the generator is the rotor. As the rotor speed rises, stresses increase at the same time that the
temperatures of the stressed regions also increase due to circulating rotor body currents. Generators
have been destroyed from this event, as extreme temperatures reduce the component material strengths.
The internal rotor components are so weakened that they cannot handle the applied loads any longer.
The result can be that the rotor wedges or retaining rings fail. Therefore protection is needed for the
generator, even when it is out of service, to prevent or at least limit motoring from rest.
Overheated ends of the circumferential flex slots can over time develop cracks in the forging,
compromising its integrity. Heating of the ends of the stator core is strongly affected by stray magnetic
flux in the end region. This field is complex and is affected by the magnitudes and angular positions of
the current in the stator and rotor windings.
- Negative Sequence Currents.

A three-phase balanced supply voltage applied to a symmetrical three-phase winding generates a
constant-magnitude flux in the airgap of the machine, which rotates at synchronous speed around
the circumference of the machine (see Fig. 1.23). In addition the slots and other asymmetries
within the magnetic path of the flux create low-magnitude space harmonics (i.e., fluxes that rotate
in both directions) of multiple frequencies of the fundamental supply frequency. In a synchronous
machine under normal operation, the rotor rotates in the same direction and speed as the main
(fundamental) flux.
When the supply voltage or currents are unbalanced, an additional flux of fundamental frequency
appears in the airgap of the machine. However, this flux rotates in the opposite direction from the
rotor. This flux induces in the rotor windings and body voltages and currents with twice the
fundamental frequency.
These are called negative-sequence currents (I2). The negative sequence terminology derives
from the vector analysis method of symmetrical components.
This method allows an unbalanced three-phase system to be represented by positive, negative,
and zero sequences. The larger the unbalance, the higher is the negative-sequence component.
There are several abnormal operating conditions that give rise to large currents flowing in the
forging of the rotor, rotor wedges, teeth, end-rings, and field-windings of synchronous machines.
These conditions include unbalanced armature current (producing negative-sequence currents),
inadvertent energization of a machine at rest, and asynchronous motoring or generation
(operation with loss of field), producing alternate stray rotor currents. As it was shown in the
previous section, the resultant stray rotor currents tend to flow on the surface of the rotor,
generating (I2)2 R losses with rapid overheating of critical rotor components. If not properly
controlled, serious damage to the rotor will ensue.

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Temperature rise measured at the end of the rotor body during short-term unbalanced load operation. (I2
given in per unit)
Value of Permissible I2 Current in a Generator
Permissible I2 as % of
Type of Generator
Rated Stator Current
Salient Pole
With connected amortisseur winding 10
Without connected amortisseur winding 5
Cylindrical rotor
Indirect ly cooled 10
Directly cooled up to 950 MVA 8
951 – 1200 MVA 6
1200 – 1500 MVA

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All large synchronous machines have (should have) installed protective relays that remove the machine
from operation under excessive negative sequence currents. To properly “set” the protective relays, the
operator should obtain maximum allowable negative sequence I2 values from the machine‟s
manufacturer. The values shown in Table above are contained in ANSI/IEEE C50.13 -1989 [2] as values
for continuous I2 current to be withstood by a generator without injury, while exceeding neither rated
MVA nor 105% of rated voltage. When unbalanced fault currents occur in the vicinity of a generator, the
I2 values of Table 4.2 will probably be exceeded. In order to set the protection relays to remove the
machine from the network before damage is incurred, but avoiding unnecessary relay operation,
manufacturers have developed the so-called (I2)2t values. These values represent the maximum time in
seconds a machine can be subjected to a negative-sequence current. In the (I2)2t expression, the
current is given as per unit of rated stator current. These values should be obtained from the
manufacturer. Table above shows typical values given in the standard .
AMORTISSEUR WINDING
Amortisseur winding for turbo generator Amortisseur winding for salient poles
Most modern rotors employ a damper or amortisseur or damping winding to dampen torsional oscillations
and provide a path for induced currents to flow. The amortisseur winding is essentially a separate
winding installed under the rotor wedges and retaining-rings that is connected similar to the squirrel-cage
of an induction motor. It produces an opposing torque when currents flow in it, and this helps dampen
torsional oscillations and add to the stability of the rotor during system stress events. In some instances,
where full-length aluminum wedges are used in the rotor, these may serve additionally as part of the
damper winding. Also some designs use the retaining-rings as the shorting connection at the end of the
rotor, instead of a dedicated component. Figure 2.46 shows a particular type of amortisseur. Photographs
of other types of amortisseurs can be seen in In addition to the above, the damper winding can help
divert negative-sequence and motoring currents from flowing in the rotor forging and causing overheating
damage. The negative-sequence rating or current-carrying ability of any rotor design is largely dependent
on the arrangement and effectiveness of the Armortisseur winding.

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F.2.2. ROTOR HYDRO GENERATOR OR SALIENT POLE

1. Rotor Cleanliness
A rotor exhibiting numerous deposits of copper powder indicate
excessive movement of the DC field coils, the excessive copper
dust should alert the inspector to possibility of the existence or the
development of shorted turn and / or ground fault.
Copper dust, iron dust, or any other telltale material my concealed
in a mixture of oil and dirt, can mask cracks on the surface of
critical components such as wedges, fan hub and blades, retaining
rings, bar connection, etc. Heavy dust deposit affect to the flow of
the cooling gas or air, in affect de-rating the machine.
The presence deposit copper or/and iron powder
cracks on the surface of wedges, blade, retaining ring etc
2. V Block Rotor Inspection

During unbalanced load or supply
condition, motoring serve or generation
with the field off (induction mode
operation), inspection of the rotor should
always include inspection of the V-Block
contact area, as well as between the
wedges themselves and between wedge
to the rotor body, its important to note
that any sign of burning / loose should
be carefully investigation.
During systems oscillation or other type
of abnormal operation, alternating current are established in the body of the rotor.
These current tend to flow along to the rotor body (pole and teeth) , along the V-Block and in the end
bells (connection rings).
When bridging high resistance contact area, these current may give rise to very localized pitting of the
metal. These high-resistance area mainly found in the contact surface between the wedge and the slot,
between different wedge, and between wedge and retaining ring.

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3. Insulation between turn

The salient pole DC field
winding come in
essentially two distinctive
designs, the strip on edge
type and the wire wound
type.
The strip on edge type ,
encounter mainly in large
hydro generator and
relatively high peripheral
speed machine, is made
out of layers of copper
strip joined at the corner or bent to form a multilayer coil around the pole.
The ground insulation is located between the coil and the side, top and bottom of the pole. In older
machine the insulation is made of mica , asbestos and fish paper bonded with shellac or order organic
materials, inrecently manufactured machine asbestos insulation has been eliminated from the list of
allowed insulation materials. The coils is insulated from the top and bottom of the pole with insulation
materials having high mechanical compression qualities, at the past is mainly asbestos board, nowdays
they are made of materials other than asbestos with similar electrical and mechanical qualities.
The wire wound pole type used mainly in similar and slower machines, is made out of preinsulated
magnet wire wound in layer of multiple turn. The turn insulation is made of aromatic paper, resin bonded
glass, mica glass, etc. the insulation between layer and layer to pole is of the kind previously for the strip
on edge type of winding.
The main problems associated with salient pole winding are due to the large centrifugal force acting upon
the winding. This force tend to distort the conductor. In addition the continuous vibration and movement
of the poles, associated with the radial clearances between pole and the winding resulting from the
centrifugal force, tend to result in abrasion of the wire and / or turn insulation. Spring mounted coil are
designed to minimize the movement and abrasion by keeping a positive force acting at all time on the
winding.
Visual inspection should search for coil deformation for insulation dust indicating excessive movement
between layers (not enough pressure) for broken or crack collars (washers) or for broken or crack or
displaced the springs (if present).
4. Starting Bars ( damper bar winding) conditions

Salient pole machine are
frequently fitted with a
starting winding. This can
take the form of squirrel
cage winding occupying the
entire circumference of the
rotor or, as with most large
machines, the starting
winding is restricted to the
pole regions. At the poles
the cage bars are
embedded in the face of the

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pole . these bars which are short-circuited at the ends, function like as induction machines squirrel cage
during start up operation, allowing machine to start from zero speed and go up nearly to full speed,
without the need variable frequency drives. In addition the bars provide electrical damping to oscillation
during the synchronous operation of the machine.
Starting (amortissuer ) winding is designed in accordance with the chosen mode of starting. For example:
some machine are designed to start at reduced voltage, while order the start at full voltage, operator error
such as higher then designed voltage starting , starting too often, prolonged asynchronous operation and
other abnormal conditions, can result in overstressing of the starting winding.
The shortcircuiting ring on one side of the cage broke loose from the bars, completely destroying the
entire end winding on that side of the stator winding.
Visual inspection is very effective in this case to assess the conditions of the damper bars. Discoloration
and / or deformation at test to abnormal operation. The bars should be checked for the crack or breaks.
In some cases removal of the paint in the region of the junction between the short bars and the short
rings allow for more effective visual inspection. If hairline cracks are suspected, non destructive (NDT)
with penetrating dye ink should be performed.
5. Bull-Ring Segment and Bracing to Starting Bars

Bull ring segments or short circuiting rings, are the electrically
active elements to which the starting bars are forced at both
ends of the machine.
As explained previously for the bars, the short circuiting
segment s should be inspected for crack and overheating, in
particularly the junction of the rings and the bars should be
closely inspected , this region most prone to failure in the
starting winding.

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G. GENERATOR PROJECT PROFILE

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FIELD PROFILE

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MATERIAL REQUIREMENT

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IV ROTOR THERMAL SENSITIVITY PHENOMENA‟S
A. Theory
Thermal sensitivity Generator rotor: thermal sensitivity is a phenomenon which may occur on the
generator rotor causing the rotor vibration to change as the field current is increased. In most cases, a
thermally sensitive rotor will not prevent a generator from running, but may limit the operation at high field
currents or VAR loads due to excessive rotor vibration.
There are many causes of high vibration on a Generator field. The most common are mechanical
unbalance, thermal sensitivity, misalignment and bearing degradation. Other causes include rubbing,
bent overhangs, rotor stiffness dissymmetry, out-of-round journals and other design deviations caused by
abnormal in service operation. Each of these causes has a predominate frequency and a characteristic
response. The cause of the vibration can be diagnosed by a thorough analysis of the vibration data. For
example, the most frequently observed cause of vibration is mechanical unbalance. This type of vibration
is synchronous; that is, the vibration frequency equals the rotor rotational speed frequency. It does not
respond to changes in operating conditions, such as generator load or field current. In most cases,
unless the unbalance is excessive, mechanical vibration can be corrected by balancing.
The remainder of this paper will only discuss generator field thermal sensitivity because it is generally the
least understood and is relatively common.
Generator Rotor Thermal Sensitivity

A thermally sensitive rotor is characterized by a once-per-revolution frequency response signature due to
a change in the rotor balance arising from the rotor bow. If the total vibration of the field stays within
acceptable limits, the field is not considered “thermally sensitive.” Vibration performance is frequently
plotted on a polar chart, because vibration is characterized by amplitude and phase angle. If the
vibration vector stays within the 2 or 3 mil circle, or whatever is chosen as an acceptable vibration
level, the vibration is not considered to be a problem. This is true even if the phase angle changes and
the vibration moves around the interior of this circle.
The change in vibration and phase angle within the polar plot from the starting operating point to the end
operating point is called the thermal vector.
There are two types of thermal sensitivity, repeatable (or reversible) and irreversible. Both types vary with
field current; however, the reversible type follows the field current as it is increased and decreased. For
example, if the vibration on a field increases from 1 mil to 3 mils as field current is increased and then
decreases in the same manner as the field current decreases, then the thermal sensitivity is considered
to be reversible. If this is the case, in many instances the field can be compromised balanced so that the
thermal vector passes mal sensitivity is referred to as irreversible or slip-stick. If this situation occurs, the
generator frequently must be taken off-line and brought down to turning gear speed to unlock the forces
that induced the rotor bow. This type of thermal sensitivity is particularly troublesome and, in a few cases,
there were no effective remedies to relieve this condition without disassembly of the winding.

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As a result, a field winding with this condition will limit load options for the owner since the generator will
not be able to operate over its full electrical capability. Figure below a plot of an irreversible field where
the vibration increased with field current but locked in at the high vibration level when the field current
was removed. through zero and the maximum vibration remains within acceptable limits.
However, if the vibration increases as the field current is

increased but does not respond to a decrease in field
current, then this type of thermal sensitivity is referred to
as irreversible or slip-stick. If this situation occurs, the
generator frequently must be taken off-line and brought
down to turning gear speed to unlock the forces that
induced the rotor bow. This type of thermal sensitivity is
particularly troublesome and, in a few cases, there were
no effective remedies to relieve this condition without
disassembly of the winding. As a result, a field winding
with this condition will limit load options for the owner since the generator will not be able to operate over
its full electrical capability. Figure above a plot of an irreversible field where the vibration increased with
field current but locked in at the high vibration level when the field current was removed.
B. Testing for Thermal Sensitivity

If a rotor is suspected to be sensitive to field current, there are tests that can be performed to confirm this
and to ensure that the condition is not due to megawatt loading of the turbine generator set. One of the
tests that is important is a flux probe test. This will give a diagnosis of the condition of the field winding
turn insulation and indicate which coils have shorts in the field winding. In most cases, the test will detect
the number of shorts present in each coil and in which pole the shorts are located. (It should be noted
that the presence of magnetic wedges may prevent accurate detection). This is an
extremely useful diagnostic test since winding turn shorts are the most common cause of thermal
sensitivity.
The other test that should be performed is one to isolate the effects of megawatt loading from VAR
loading on the field. Vibration changing as a function of megawatt loading is not a thermal sensitivity
mechanism. Megawatt loading may result in rotor vibration excursions as a result of bearing alignment
shifts. The three-part thermal sensitivity diagnostic test is shown graphically.
The first part of the test is to apply constant field current to the field and then to vary the megawatt
loading on the generator from 15–60%. Detailed vibration readings as well as other key generator
parameters, such as generator voltage, currents and temperatures, should be monitored throughout all
stages of the testing.
Any significant changes in the generator vibration during any part of the testing should be noted. This first
part of the testing would correspond to moving from point 1 to point 4 on Figure below.

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The second part of the test is to apply a constant

megawatt load to the generator (approximately 60–
80%) and then raise field current to maximum rated
field current. Each test point should be held until
steady state is reached. If the unit is unable to reach
maximum field current attainable without a Vibration
excursion, the series should be repeated but be
limited to the maximum field current attainable
without exceeding acceptable vibration limits. Again,
detailed test data should be taken. A significant
change in vibration or phase angle with an increase
in field current at constant megawatt
load would indicate that the field is thermally
sensitive.
This test should then be reversed; that is, decrease field current from its maximum value back down to
the starting point. Again monitor all test data. If the vibration and phase angle return to their initial values,
then the type of thermal sensitivity can be considered reversible and, in many cases, can be overcome
with a compromised balance that moves the thermal vector through zero so that vibration limits are not
violated. However, if the vibration levels do not return to the original values and remain high, then this
field vibration is considered to be irreversible and corrective actions may involve modification to the field.
C. Causes of Thermal Sensitivity

It was mentioned previously that one of the prime reasons that generator fields are thermally sensitive is
because of the large difference in coefficients of expansion between the copper conductors that make up
the winding and the steel field forging. Whenever field current is applied, the copper tends to expand
more than the steel forging. As field current is increased to large values that approach the rating of the
unit, the difference in expansion between the copper and the steel can become significant and the forces
generated large. If these forces are not distributed uniformly around the field circumferentially, they can
cause the generator rotor to bow. This bowing is what causes the thermal sensitivity and it varies as field
current is increased or decreased. This principle is simple, but because of the complex configuration of a
generator field, there are many things that can influence and affect the susceptibility of a given field to
thermal vibration. The following are some items which by themselves or in combination can cause a
generator field to be thermally sensitive.

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1. Shorted Turns
Shorted turns occur when there is a breakdown in the insulation between turns. They are the most
common cause of thermal sensitivity. Depending on the distribution and number of shorted turns, there
may or may not be an operating problem. Shorted turns in the coils adjacent to the poles are most
significant. When there are shorted turns in a field, the pole of the field that has the higher number of
shorted turns, there may or may not be an operating problem. Shorted turns in the coils adjacent to the
poles are most significant. When there are shorted turns in a field, the pole of the field that has the higher
number of shorts has a lower electrical resistance and, as a result, will be at a slightly lower temperature
than the opposite pole. Therefore, the higher temperature pole will elongate in the axial direction more
than the other pole and, as a result, the field will bow in that direction. (See Figure.) As field current is
increased, the amount of bowing will increase and the field vibration and phase angle will be similarly
affected. Shorted turns result in a reversible thermal sensitivity.
2. Blocked Ventilation or Unsymmetrical Cooling

Blocked ventilation,
like shorted turns,
can significantly
affect the
circumferential
thermal balance of
a generator field.
This could occur if
a foreign object were introduced into the field and disrupted the normal ventilation and cooling of the field.
Direct-cooled windings are cooled by the cooling medium passing directly through holes that are
designed and manufactured into the copper. A shifting of the insulation or plugging of these cooling
passages could cause these fields to become thermally sensitive.
The uneven temperature distribution would affect a field in the same manner as shorted turns. This type
is reversible. And see pages 36

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3. Insulation Variation
Insulation Configuration and Clearances Must Be Uniform in All Slots
If a field is not wound uniformly from pole to pole in regards to

insulation thickness and buildup, binding and uneven friction forces in
the coil slots and under the retaining rings could result. Should this
occur, the field coils might not be free to expand uniformly in the axial
direction as field current is applied and, as
a result, the field forging may be loaded unevenly and cause the field
to bow. In this case, the coils with the highest friction or the ones that
are binding will apply more load to the forging in the axial direction
and cause the field to bow in that direction. Increasing the field current will cause the bow in the field to
increase further. In some cases, the conductors in some slots may slip and cause a step change in the
vibration. In other cases, the binding of the coils will persist and the rotor will remain bowed even after the
field current has been removed. This condition has occurred on fields that have been in service for many
years as the insulation has broken down or migrated and shifted in the slots. Care must be taken in the
assembly of new fields and during field rewinds to ensure that the insulation is installed uniformly and
according to proper design procedures and clearances. In many cases, this type of thermal sensitivity is
considered irreversible or slip-stick.
4. Wedge Fit
Generator rotors can become thermally sensitive if

wedges are modified or replaced. This is especially
true when only a portion of the wedges is replaced,
such as a slot or two-in-one pole. If the tightness of the wedges does not remain uniform, then it can
cause binding in the axial direction which could lead to bowing of the rotor. If wedges are replaced or
modified, it is very important that this be performed carefully so that all wedges in the field have the same
clearances and fit. This condition usually produces irreversible thermal sensitivity.

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5. Distance Block Fitting

The distance blocks that
provide the spacing in the
generator field end
windings must be spaced
and fit properly. Uneven
spacing and/or fitting can
cause non-uniform forces
to be transmitted into the
field forging through the
retaining rings or centering rings and, like all the other possible causes of thermal sensitivity, make the
rotor bow and change dynamic characteristics. Uneven distance block fitting will cause reversible
vibration.
6. Retaining Ring/Centering Ring Assembly Movement
Significant forces from the field coils are transmitted into the retaining ring and centering ring as field
current is increased. If these rings are not installed properly, the field can be non-uniformly loaded and
cause the rotor to bow. Also, if the shrink fit is insufficient, these rings can move on their shrink fits and
cause a change in center of mass of the retaining rings. In this case, the field vibration signature will be
variable and the problem cannot be resolved until the light shrink is corrected. It should be noted that
rotors that have spindlemounted retaining rings as compared to those that are body-mounted are much
more susceptible to thermal sensitivity since the retaining rings are mounted on the more flexible spindle
section of the shaft. Because of this, for the same amount of axial force, a spindle-mounted rotor will bow
to a much larger extent. (See Figure above.) Movement of the retaining ring and/or centering ring can
cause reversible and irreversible vibration.

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7. Tight Slots
This rare condition will usually occur
if, during a field rewind, the insulation
system is changed and/or the copper
is reused and is no longer flat due to
distortion caused by handling and
operation. It is important that the
required design clearance is
incorporated in a field rewind. Tight
slots will cause the copper to move unevenly in the axial direction as field current is applied and result in
rotor bowing. This condition typically causes the irreversible type of vibration.
8. Heat Sensitive Rotor Forging

GE has no generator rotors that have exhibited heat sensitive rotor forgings. However, other
manufacturers are reported to have experienced this phenomenon. This rare condition occurs due to
non-uniform material characteristics throughout the generator rotor forging and has no relation to the
configuration of the field or the copper. Because of the non-uniform properties, as field current is applied
the rotor forging expands unevenly in the axial direction and causes the rotor to bow. This condition is
caused by problems in the manufacture and heat treatment of the forging at the material vendor.
The preceding causes for generator rotor thermal sensitivity are those that are most commonly
encountered, but are by no means a complete listing. Other things which can cause dissymmetry, such
as misuse of adhesives, use of incorrect materials and some types of misoperation, can also cause fields
to be thermally sensitive.
Anything that creates non-uniform heating, expansion forces, friction, etc., as field current is changed can
result in thermal sensitivity. In some cases, the problem is not due to just one of the above or other
causes, but a combination of them. As mentioned previously, all rotors have some degree of thermal
sensitivity. The key is to control the level of sensitivity through good design and manufacture.

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D Project Experiences
1. BACKGROUND
This generator is H2 cooled; following items was recorded during in maintenance:

 H2 plant problems, generator was operated with H2 low pressure in app, 20 – 25 psi (no
record reported how long this generator running with H2 low pressure ).
 Magnetizing, found magnetizing on the shaft at turbine end.
 Vibration, Generator vibration with causing to change as the field current is increased
(increasing of MVAR load), some test was carried by user out with thermal sensitivity
suspect.
 Field current, Generator is requiring higher excitation current with same load comparing
to the generator record before generator problems.
Generator data:
Name plate data

Maker__________________ : General Electric
Type __________________ : T 273
Year __________________ : 1993,
Output_________________ : 237.5 MVA
PF_____________________ : 0.8
Speed_________________ : 3000 RPM
Freq _________________ : 50 Hz
Voltage ________________ : 15000 volts,
Current ________________ : 9141 A,
Insul Class _____________ : F,
Phase Connection________ : Y,
Rotor :
No of poles______________ :2
Exc Voltage _____________ : 550 V
Exc Current _____________ : 1562 A
Insul Class _____________ :F

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2. LOADING DATA BEFORE REPAIR
Loading Data, :
Field Field
Loading Vibration
Data No Voltage Current
MW MVAR Volts Amperes BB5X BB6X
Data 1 93.4 30.0 204 854 NA NA
Data 2 95 10 183 875 0.108 0.076
MW Based load 185 100% Full Load MW

Data 1 93.4 50.5% Before Problems
Data 2 95 51.4% Problems
% MVAR Load to based load 138 100% Full Load MVAR

Data 1 30 21.96% Before Problems
% Field Current (AFFL) 1471 100% 100% AFFL

3. Rotor Removal
Site finding
Rotor to be repaired with complete copper rotor winding to be removed, following items activities
were done being repairing:
 Remove both retaining rings

 Remove all of steel wedges
 Complete removal rotor copper bars
 Remove all rotor insulation
 Replace slot liner insulation
 Replace all turn insulation
 Replace all retaining rings insulation
 Cleaning all copper bars rotor winding

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 NDT inspection on rotor forging and retaining rings, steel wedges, etc
 Degaussing on rotor forging, journal shaft, bearings, turbine HP/LP, etc
4. THERMAL SENSITIVITY TEST AFTER REPAIR
a. Dynamic testing.
Generator vibration was monitor by ADRE Data Acquisition 208 Bently Nevada, and DCS
control, vibration was monitor during generator without excitation with air-cooled and H2 cooled,
and excitation with H2 cooled.When the generator has been energized the initial excitation
vibration level at bearing 6X No has no changed, bearing 5X decrease from 60 to 50 µ .
a.1. Testing Step 1. apply constant field current to the field and then to vary the megawatt
loading on the generator from 15–60%.Due to load system is to be set automatically, manual
setting to get a constant field current is difficult, based on this condition the load percentage load
level during test has been set as per operation systems required, however field constant current
setting is chosen as close to test recommendation.
Field constant current has been set by chosen with vary megawatt and megavar loading.
Field current test .
(test point 1 ) : 722 A, MW : 34.3 or 18.5%  H2 pressure was increased from 15 PSI to 30 PSI,
the vibration level at bearing 6X was decrease from 106 to 82.2µ.
(test point 2 ) : 770 A, MW : 61 or 33%
(test point 3) : 763 A, MW : 75 or 40.5%
(test point 4) : 732 A, MW : 81.2 or 43.9%
Each step test has been maintained 6 hours until the vibration level reached steady. Maximum
vibration level during this test is 90µ <700 at bearing 6X, with initial vibration level is 82.2µ.˂660
This test is purpose to analyze of vibration change based on the MW load change
a.2. Testing step 2 : is to apply a constant megawatt load to the generator (approximately 60–
80%) and then raise field current to maximum rated field current. Each test point should be held
until steady state is reached. This test should then be reversed; that is, decrease field current
from its maximum value back down to the starting point.
This test to be done after test 1 has been finished, and the maximum MW load at test 1 to be kept
for this test and vary MVAR was set as much as can achieved with cos Φ = 0.8, starting from cos
Φ = 1, and than to be reversed with decreased the MVAR value back downward to the starting
point.

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MVAR load were chosen as a Cos Φ increment step balance,

Cos Φ = 0.999 MVAR = 4.2,  is not possible to set “0” MVAR
Cos Φ = 0.927 MVAR = 33.5
Cos Φ = 0.863 MVAR = 48.6
Cos Φ = 0.806 MVAR = 61
Each step test has kept until the vibration level steady, and than test was reversed with
decreased MVAR.
The highest vibration level has reached when MVAR load at Cos Φ = 0.806, is 150µ <79 0 at
bearing 6X and 60µ <660
Thermal vibration vector based on these test are :
Bearing 5X = +/- 66µ Max limit for thermal vector = 76.2µ
Bearing 6X = +/- 62µ
Detail see Annex:
b. Static Testing
Static test was perform during rotor stand still especial for RSG was tested for dynamic when
rotor rotate at 2500 RPM and 3000 RPM.
b.1. Winding Resistance test

During this test, the measurement of the ohmic value between terminals winding is carried out.
Given the relatively low series dc resistance of winding.
The purpose of this test is to detect shorted turns, bad connections, wrong connection and open
circuit. Acceptable test result consist of three resistance value each phase to be balanced in
according standard.
The machine should be in room temperature when the test is performed. test should be applied
on the Stator winding and rotor winding, test will be referred to Factory measurement and
International Standard NEMA MG-1, EASA, IEEE and factory measurements.
The resistance should be corrected to temperature:
Rt2 (t1  k)
Rt1 
(t2  k)
When the resistance, Rt2 : of a winding has been determined by test at winding temperature,
t1 : the resistance may be corrected to a specified temperature, t2 : the temperature test of
winding. k : is 234.5 for 100% IACS conductivity copper, or 225 for aluminum, based on a
volume conductivity of 62%.

Page 132 of 142
2008
Rdc at 28 C = 0.20945 Ω
Factory measurement at 1250C = 0.320
Site measurement after correction to 1250 C = 0.31691 Ω
% deviation based to factory measurement = 0.87%
b.2. RSO inspection when rotor standstill

The “Generator Rotor Shorted Turn Analyzer” or (“RSO” Recurrent Surge Oscillation) produces a
succession of step-shaped low voltage pulses. The pulses are introduced simultaneously to the
dc rotor winding (“field winding”) from both ends. The resulting reflected signals can be viewed on
a dual channel oscilloscope screen as two separate waveforms, or after one of them is inverted,
and both summed as a single trace.
If no discontinuities are present in the winding (due to grounds or shorted-turns), both traces will
be nearly identical and if inverted and summed, a single trace will be displayed as a horizontal
straight line, with a minor blip at the origin and an almost imperceptible ripple. Any significant
discontinuity arising from a fault will be shown as an irregularity on the summed trace. By
estimating the location of the anomaly on the screen, an inference can be made as to the
approximate location of the fault. For instance, large irregularities near the origin of the trace are
attributed to faults close to either end of the winding.
Figure 1 below shows the typical connection arrangement:

Sliprings
Ground
wire
RSG 220
Vac
Oscilloscope
RSO wave pattern when rotor standstill

Page 133 of 142
2008
b.3. RSO inspection when rotor to be rotated up to 3000 RPM

Some winding rotor fault can not to detect when rotor stand still due to there is no mechanical
load on the winding turn. Inter turn or ground short are sensitive to speed, RSG inspection during
rotor spun is advantage, because when rotor spun all of winding rotor have a mechanical load
and centrifugal force
RSO inspection when rotor to be spin 2500 RPM.
RSO inspection when rotor to be spin 3000 RPM
c. Loading Data and thermal vector record :
Field Field
Loading Vibration
Data No Voltage Current
MW MVAR Volts Amperes BB5X BB6X
Data 1 93.4 30.0 204 854 NA NA
Data 2 95 10 183 875 0.108 0.076
Data 3 83 33.5 215 889 0.03 0.11

Page 134 of 142
2008
MW Based load 185 100% Full Load MW

Data 1 93.4 50.5% Before Problems
Data 2 95 51.4% When Generator Problems
Data 3 83 44.9% After repair
% MVAR Load to based load 138 100% Full Load MVAR

Data 3 33.5 24.28% After repair
% Field Current (AFFL) 1471 100% 100% AFFL

Data 3 889 60.4% After repair
Vibration Record
0.66 mm
0.62 mm
vibration monitor by ADRE Data Acquisition 208 Bently Nevada, and DCS control

Page 135 of 142
2008
The two individual tests (TEST 1 and TEST 2) confirmed the generator rotor is stable and within an
acceptable standard. The OEM limit of between 2 to 3 MILS (0.50 to 0.75 mm) was not exceeded and
therefore this rotor cannot be considered „thermally sensitive‟.
TEST 2 was solely undertaken to prove to the customer that the generator rotor after the rewound
programme was not thermally sensitive. This test placed the rotor under an extremely high MVAR status
that is not normally experienced during normal operational requirements of the unit. Under a TEST 2
condition, any generator rotor will experience some form of vector change because of the high current
applied to the rotor but providing these vectors do not exceed the acceptable limit of 3 MILS, the rotor
can be classified as acceptable.
After TEST 2 the unit was returned to the customer since there was a need for commercial power. A
compromise was taken with the customer to complete the RotorPro test programme and then to have the
generator made available for commercial service. This compromise saw the unit been placed at 140 MW
and 0 MVARS for the next six hours, thereafter the unit was made available to the customer to meet their
commercial power demands.
Prior to completing this report, the writer was informed that the highest vibration level from the generator
during its commercial service was 0.10 mm. Since the unit meets the vibration specification requested by
the customer for the rewound programme it seems commercially pointless to undertake a further balance
exercise to „offset‟ the acceptable vibration vectors on this rotor. A single balance correction is expected
to take a few days and there is very possibility that more than one weight set correction will be
necessary.
Now that the unit has been in commercial service there is the possibility to complete the RotorPro test
programme, which requires the „over-speed‟ operation. This ‟over-speed‟ is to settle the CRR‟s and the
copper windings after which the vibration levels are re-valuated. Based on the vibration results after the
„over-speed‟ programme further recommendations will be proposed to the customer should this be
necessary.

Page 136 of 142
2008
Reactive Capability Curve GE Generator 237.5 MVA / 15.5KV/3000 RPM

Page 137 of 142
2008
Excitation V Curve, GE Generator 237MVA / 15.5kV / 3000 RPM

Page 138 of 142
2008
5. START UP PROCEDURE
This is the recommended step-by-step procedure for the commissioning and balancing (if necessary) of
the generator rotor of the above-mentioned unit.
a. The run to speed (3000 rpm) of the unit is undertaken by the operator. The limitation during the
transient (i.e. run up behavior) event is the maximum shaft vibration level and this is not to exceed
180 micrometers peak to peak (0.18 mm). This run up event is to be undertaken with the
generator rotor in air, if this is possible. During this programme BRG 4, BRG 5 and BRG 6 will be
monitored with the portable analyzer.
b. If generator vibration levels reach 180 micrometers during the run up, the unit is to be run down
and another attempt made to reach full speed. This is to confirm vibration repeatability behavior.
c. If generator rotor requires balancing then a balance procedure will be undertaken. Calibration
weights need to be fitted to the fan balance ring and the unit returned to speed. Based on the
results of this calibration weight, additional weight corrections will be necessary and additional run
to speed of the unit until <180 micrometer pp is achieved. Depending on results, this procedure
may take between 2 to 4 individual runs. After balancing the stator is to be hydrogen filled and
customer to undertake their respective tests to ensure unit is ready to be placed into service.
d. Once the generator rotor achieves full speed with vibration levels (<180 micrometers pp), the rotor
is to remain in the unexcited condition to allow temperatures, pressures etc to stabilize.
Anticipated time will be approximately 2 hours.
e. Generator Load Conditions: Apply full machine voltage and wait for stabilization. Synchronize
unit and maintain the applied load for 6 hours.
f. Generator Load Steps: These steps are at 20% increments and maintain unity. Anticipated
time will be approximately 6 hours per step. Should vibration levels exceed 180 micrometers pp,
the load procedure is to be stopped and the generator rotor re-assessed. This may include a
reverse in the load programme and/or run down/run up event.
g. Generator load to be taken to maximum (185 MW) at unity through the 20% steps.
h. Unit to be handled over to Operations. If „over-speed‟ test (10%) is done then the vibration levels
to be re-assessed once the generator rotor is returned to full speed. Due to this large mass
across the poles, is expecting the copper windings to eventually shift and finally settle (either
during the load programme and/or the „over-speed‟) which will mean that the rotor will need to be
re-balanced.
6. ANNEX : DATA TEST THERMAL SENSITIVITY

Page 139 of 142
2008
E. References
This hand out has been compiled referring to the following reference literatures and project
experiences during inspection, repairing, rewinding of generators in Indonesia.
1. Private Project experiences during inspections, repairing, rewinding of power generation with
various capacity from 10 MVA up to 250 MVA, salient poles and cylindrical pole generator in
Indonesia.
2. IEEE 43 – 2000, Recommended Practice for Testing Insulation Resistance of Rotating Machinery
3. NEMA MG 1. Motor Generator
4. ANSI / EASA AR100-2006: Recommended Practice for Repair of Rotating Electrical Apparatus
5. VDE [Verband Deutscher Electrotechniker] 0530
6. EPRI Power Plant Electrical Reference
7. Isidor Kerszenbaum. IEEE Power Engineering Series , Inspection of Large Synchronous

Machine
8. Maughan Engineering Consultants, Schenectady, New York , Visual Inspection of Large

Electric Generator
9. Electro Mechanical Engineering Associates. Pittsburgh, PA, Generator Core Investigation
10. Ronald J. Zawoysky, William M. Genovese. Generator Rotor Thermal Sensitivity -, GE Power
Systems,Schenectady, NY
11. Dean T. Roney, Ronald J. Zawoyski. Generator In Situ Inspection, , GE Power Systems,
Schenectady, NY
12. Ronald J. Zawoysky, Karl C. Tornroos, GE Generator Rotor Design, Operational Issues and
Refurbishment Option, GE Power Systems, Schenectady, NY
13. Dan Huynh and Terry Hill, Hugh Zhu. EXPERIENCE WITH DIAGNOSTIC TESTING TO
EVALUATE THE REMAINING USEFUL LIFE OF A HYDROGEN-COOLED GENERATOR ,
14. Hugh Zhu (Ph. D., P. Eng.), Vern Buchholz (P. Eng.) Insulation Condition Assessment of
Generators and Motors, Powertech Labs Inc, Canada.
15. TOSHIBA CORPORATION, Technical Information Letter For Preventive Maintenance of 125 and
250 MVA Turbine Generator (TIL No. ECS – 990506P)
16. Clyde V, Maughan P.E. Upgrading of Generators to Improve Reliability, Maughan Engineering
Consultants, Schenectady, New York 12306 USA.

Page 140 of 142
2008
17. Advanced Non Destructive Inspection For Turbine Generator Components. TOSHIBA
Corporation, Keihin Product Operation, Yokohama 230-0045, Japan.
18. DR Hassan EL-Kisky, Beant Nendra P.E. The Development And Evaluation Of Anti-Corona
Systems For High Voltage Rotating Machine, National Electric Coil, Inc, Brownsville,
19. Clyde V. Maughan P.E. Testing Of Large Electric Generators For Suitability Of Service, Maughan
Engineering Consultants, Schenectady, New York 12306 USA.
20. R. Albright, David J. Albright and James D. Albright. GENERATOR FIELD WINDING
SHORTED TURN DETECTION TECHNOLOGY, Donald Generatortech, Inc.
21. Bill Moore, P.E Refurbishment Solutions for Various Field Pole Problems,.. National Electric Coil.
800 King Ave. Columbus, OH 43212 614-488-1151
22. G. Klempoer. Rotor Shorted Turns – Detection and Diagnostics” EPRI – International Conference
on Electric Generator Predictive Maintenance and Refurbishment. January 20-21.2003 / Orlando
Florida.. Kinectric Inc.
23. G.C. Stone S. Iris Power Engineering , Cherukupalli B.C. Hydro, “A NEW IEEE STANDARD
FOR VOLTAGE ENDURANCE TESTING of HYDROGENERATOR STATOR COILS”.
24. Wood Group Generator Services, Inc. 1113 Camina Entrada Farmington, New Mexico 87401
MEGA-Pac™:Resin-Rich Windings.
25. ADWEL Corona Probe, Model PPM-97. ...off-line test for precise locating of sources of partial
discharge operation manual.
26. Sumatron. Inc. INSTRUCTION MANUAL GENERATOR ROTOR SHORTED TURN ANALYZER
FOR TURBO-GENERATOR DC-FIELD WINDINGS
27. Rotor Pro Power Generation Services Company Profile, Johannesburg, South Africa.
28. Clyde V. Maughan P.E. VISUAL INSPECTION OF LARGE ELECTRIC GENERATORS.

Maughan Engineering Consultants. Schenectady, New York 12306..
29. Brad McNamara, P.Eng.. John Maybury LIMITED ACCESS INSPECTIONS OF

HYDROGENERATORS. ADWEL International Ltd.
30. ISOVOLTA AG. A-2355 Wiener Neudorf. E ISOSEAL MF 0611_MF ME 2411 a, Electrical
Insulation and Rigid Lamination.
31. Von Roll Isola Catalogue. Ref : E 002.1411.CS.

Page 141 of 142
2008
32. IEEE Std 112-1996 “Standard Test Procedure for Polyphase Induction Motors and Generators.
33. Greg C. Stone. Recent Important Changes in IEEE Motor and Generator Winding Insulation
Diagnostic Testing Standards. Copyright Material IEEE. Paper No. PCIC-2004-XX IEEE Fellow.
Iris Power Engineering. 1 Westside Drive, Unit 2. Toronto, Ontario M9C 1B2. Canada
Jakarta, March 2008 edited October 2010
Siswanto
Specilaist Engineer
Power Generation Services
Mobile phone : +62 81 311422270
Emails : [email protected]
[email protected]
Blog : www.sispowergeneration.blogspot.com
Member of CR4.globalspec.com
http://cr4.globalspec.com/member?u=14927

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Turbo / Hydro Generator Stator - Rotor Winding Construction

March – 2008 edited October 2010

[Generator rotor thermal sensitivity is a phenomenon found on the

Compiled by : Siswanto , March 2008,

B Summary of HV coil test specification 20 – 23

Compiled by : Siswanto , March 2008,

III INSPECTION AND TESTING 43 – 121

Compiled by : Siswanto , March 2008,

Compiled by : Siswanto , March 2008,

IV ROTOR THERMAL SENSITIVITY PHENOMENA‟S 122 - 128

Compiled by : Siswanto , March 2008,

8 Heat Sensitivity Rotor Forging 128 – 128

E REFERENCES 140 - 142

Compiled by : Siswanto , March 2008,

1. Class A: Permissible Maximum temperature winding = 1050 C

Type Enamel Base Class Application

Soldex 155 Modified polyurethane F Solder able

Thermex 180 Modified polyesterimede H Transf. Motors

Thermex 220 Modified polyamideimide C Nuclear application

High thermal stress

Compiled by : Siswanto , March 2008,

Table. A.2__ Wire paper insulation application

Type Description Class Application

Double Fiber Glass Varnished Fiber glass filament F DC field winding

NOMEX ® (Aramid 0.005” (0.127mm) bonded to H Transformer, Magnet coil

Compiled by : Siswanto , March 2008,

A.2. Winding Constructions

Fig.A.1 Stator winding construction in the slot.

Stator Core Separator

Side Ripple Radial Spring

Semiconductive Bar Armor

Solid Copper Strand

Compiled by : Siswanto , March 2008,

Fig. A-2. Stator Winding Insulation Construction

A.2.1. Coil Material Properties in History

For old machines (build within year 1930s) the

Compiled by : Siswanto , March 2008,

A.2.2. Coil winding construction step-by step manufacturing process. :

1. Copper strip (wire strand)

2. Strand / Turn insulation

Compiled by : Siswanto , March 2008,

Fig A-5. Looping winding

Fig A-6 Roebel forming winding (manual machine)

Compiled by : Siswanto , March 2008,

Fig. A-7 . Robotic Roebeling machine

Fig. A-8. Roebel Winding

Compiled by : Siswanto , March 2008,

Stator conductor bar cross sections. (a)

Fig. A.9. Roebbeling coil form

Compiled by : Siswanto , March 2008,

Fig A-10: Coil Spreading

6. Coil Shape Check

Fig A-11 : Coil shape ceck in the “Mock Stator”

7. Ground wall insulation

a insulation tapping systems

a.1 Wrapping by discontinuous method

Compiled by : Siswanto , March 2008,

a.2. Wrapping by continuous method

Fig A-12 : Wall insulation tapping by tapping machine