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Abstract:
Generators are subjected to high electrical, thermal and mechanical stresses over the course of
their service life. Continuous extreme thermo-mechanical stresses and thermal cycles can have
a particularly severe impact on the stator core. Over time, this can lead to deficiencies in the
core insulation. A damaged insulation can cause the formation of larger eddy currents and local
hot spots, which spread out during time.
Therefore, it is recommended to regularly check the insulation condition, to avoid possible
consequential damage such as core burning or damage of the insulation.
The flux test is used to measure the condition of the stator core insulation and to detect possible
local insulation damage. Local hot spots caused by insulation failure between several sheets of
the core during magnetization will be detected by the infrared imaging instruments.
For evaluating the condition of generator stator cores, three test methods exist:
Electromagnetic core imperfection detection (EL-CID)
50-60 Hz ring flux testing
500 Hz ring flux testing
The information contained in this article is a brief discussion of the EL-CID test technique, 50-60
Hz ring flux testing and 500 Hz ring flux testing.
Key words: EL-CID, stator core, ring flux testing, Insulation Tester, DC Hipot test sets
1. Introduction
Generator which is the key component of a power plant must be safe and reliable. To ensure
this, the condition of the generator must be checked regularly and inspections planned
predictively. The stator core of the generator is constantly under a load during operation and
ages as the result of mechanical, thermal, and electrical stresses. In particular, the insulation
between the many thousands of individual laminations may be damaged. Damaged insulation
can result in higher eddy currents and local hot spots, which gradually spread to a core burning
or interturn faults around the stator core, even to complete failure of the machine.
Fig. 1 Possible forms of damage and traces of burning to the stator core
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APT Power Technology Co.,Ltd, Xian April,2017
Three measurement methods are in use globally for assessing the condition of the stator core,
each of which will be studied and compared in this paper. Two of these methods deliberately
generate hysteresis and eddy current losses in the stator core in order to create hot spots at
defective points and detect them by means of thermal imaging.
The Chinese National Standard GB/T 20835-2016 Guides for magnetization test of generator
stator core shows the test procedure of the generator stator core by the ring flux testing method,
and EL-CID is mentioned in the appendix.
The international standard IEEE Std 56-2016 Insulation Maintenance of Electric Machines and
IEEE 56-1997 Guide for Insulation Maintenance of Large Alternating-Current Rotating
Machinery (10,000 kVA and Larger) also show the ring flux test of the generator stator core
during the maintenance.
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APT Power Technology Co.,Ltd, Xian April,2017
Examination of each slot together with its adjacent teeth results in overlapping that provides
additional information about the defective points.
The measurement signal is split by a signal processor into one component in phase with the
excitation field and one component caused by the fault current. To split the signal, a phase
reference is required, which can, for example, be determined from the current of the excitation
winding.
Fig. 5 the Iris Power EL CID Evolution Fig.6 the vehicle of Chattock Potentiometer
Fig.7 the hot spots color map display Fig.8 EL-CID signal interpretation of
surface and deep faults
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APT Power Technology Co.,Ltd, Xian April,2017
Traditionally stator core inter-laminar insulation testing has been done using the ring or loop
ux test method, in which rated or near-rated ux is induced in the stator core yoke. This
corresponds to a magnetic induction of up to 1.3 Tesla or approximately 100V/m of induced
longitudinal voltage.
Fig. 9 shows the stator magnetic flux during operating and during inspection. The induced flux
in turn induces circulating currents from the faulted area usually to the back of the core. These
circulating currents cause excessive heating in areas where the stator iron is damaged. The
heat produced is generally detected and quantied using established infrared techniques. Fig.10
is the thermal imaging hotspot analysis.
This method has been proved to be successful over the years, but it requires a large power
source and considerable time, manpower and resources to complete. Fig.11 shows the basic
setup of a rated flux test.
Fig. 9Magnetic flux during operation (left) and during inspection (right)
6. References
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Supplier
Tooth top Slot ground Tooth top Slot ground
recommended
Item horizontal horizontal vertical vertical
limit values for
position position position position
fault detection
100 mA at 5 V/m
EL-CID test 35 mA 40 mA 60 mA 65 mA
excitation
Ring ux test at
10 K: permanent
rated frequency Temperature rise Temperature rise Temperature rise Temperature rise monitoring
B=1.3 Tesla 22 K 52 K 26 K 58 K 20 K: repair
(105 V/m)
500Hz
Ring ux test at Temperature rise Temperature rise Temperature rise Assessment:
Temperature rise
rated frequency 11 K 15 K 9K >10 K: repair
10 K
B=1.3 Tesla
(105 V/m)
Table 2: Comparison of limit values for fault detection
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APT Power Technology Co.,Ltd, Xian April,2017
6. Conclusion
The EL-CID test provides rapid testing of the machine, often less than one work shift for turbo
generators and motors. The Ring Flux test typically takes 3 work shifts. The typical labor is
reduced than the Ring Flux test, and rapid setup to retest after any repairs ensure quick
turnaround. It is safe for core and operator, unlike Ring Flux test which is potentially damaging
to the uncooled core.
Both 50 Hz flux test and testing at higher frequencies of 500 Hz are suitable methods for
detecting defects in stator cores.
The stator core test using the EL-CID method is, however, less suitable because here the stator
core cannot be tested under realistic operation conditions and the measurement result has to be
interpreted. Defects may then be overlooked and incorrect assessments made.
The 500-Hz test produces results comparable with the established test at 50 Hz, but is
considerably easier to implement due to the lower power losses and considerably lower
apparent powers. Its advantages include, in particular, the considerably smaller test setup, the
concomitant simpler transport and possibility of connecting it to the 400-V grid.
7. References