Overview of Shorted Turn Theory & Flux

Probe Testing
A flux probe test determines the existence of rotor winding shorted turns by measuring the
magnetic flux produced by each coil in a generator's rotor.

The amount of magnetic flux produced by a coil is the product of the current and number of
active turns in the coil (amp-turns or magnetomotive force [MMF]). If a shorted turn is
present, the number of active turns in a coil is reduced and the resulting decrease in
magnetic flux produced by the coil can be determined by analysis of the flux probe waveform.

In order to get the best sensitivity for detecting shorted turns in all rotor coils, a series of
loadpoints is recorded as the load on the unit is varied.

The flux density curve zero-crossing (FDZC) position will vary based on the loadpoint. The
value of the FDZC will vary from 1 to n (where n is the number of coils in the generator). A
waveform's FDZC value will directly correspond to the coil with the maximum sensitivity for
detecting shorted turns.

The coils that are further away from the FDZC position will have decreased sensitivity for
detecting shorted turns due to a combination of magnetic flux saturation of the rotor iron and
modulation effects.

See the movement of the FDZC as the load moves from no-load to full-load.
 Shorted Turns: Cause & Effect
Shorted-turns are the result of failed insulation between individual windings in generator
rotors. Stop-Start cycles, line disturbances, contamination, moisture, manufacturer error and
damage during retaining ring installation are some of the reasons insulation fails.

The impact of operating with shorted turns ranges from no-problem to abnormal vibration,
load limits, higher operating temperatures and forced outages.

The location and number of shorted turns in a rotor determines the magnitude of the effects
of running a rotor with shorted-turns.

As generator units age, shorted-turn problems are more likely to be experienced. The
stresses involved in each Stop-Start cycle play an especially important role. Occasionly,
newly rewound fields will have shorted-turns.

Shorted-turns in the field winding can cause operating conditions which may limit unit loads.
If conditions are extreme, forced outages may occur.

The effects include:

- Rotor unbalance that varies with field current changes

(thermal sensitivity and/or magnetic unbalance). .....

- Higher field current is required than previously experienced at a specific load.

- Higher field currents result in higher operating temperature.

- Decreased power generating efficiency.

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Rotor unbalance that varies with field
current changes (thermal sensitivity
and/or magnetic unbalance).

Coils with shorted-turns operate at lower temperatures than coils without shorted-turns. This
is because the heating resulting from I2R losses are lower in the effected coil (the coil current
is traversing a shorter copper path, thus R is lower for the coil), while the cooling circuits
remain the same. The rotor temperature gradient responsible for rotor bowing will be a
function of the number of turn-shorts, their location (refer to Figure 1 below) and the
magnitude of the field current (which varies with load). Shorted-turns in coils near the
quadrature axis in 2-pole rotors will have little effect on thermal sensitive balance because
the effected slots are nearly 180° apart. Shorted-turns in the small coils (1, 2 or 3) of one
pole will have a greater effect in causing rotor unbalance problems since the rotor
temperature gradient will be more asymmetrical.

Figure 1 - Field Nomenclature for 2-Pole Rotor

Shorted-turns in 4-pole rotors will cause unbalanced magnetic forces. These unbalanced
magnetic forces cause rotor vibration along the pole axis that has the turn shorts. Shorted
turns in 2-pole rotors do not generally cause an unbalanced magnetic force as the N-S poles
are 180 mechanical degrees apart.
Figure 2 - Field Nomenclature for 4-Pole Rotor

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Higher field current is required
than previously experienced at a specific
load

When shorted-turns occur, higher field current is required to maintain a specific load.
Excitation capacity may limit load if greater than 5-10% of the field winding is shorted out.
The Amp vs. Field-Turn relationship is AS = ANTN/TS where AS and TS are the field current and
active turns in a rotor with shorted-turns and AN and TN are the same in a rotor with no
shorted-turns. The field winding loss (I2R) at a specific load can be determined by noting that
the resistance of the field winding will decrease by TS/TNbut the I2 component increases by
(TN/TS)2. This results in an increase in the field winding loss of TN/TS for a specific load.

For example, two turns shorted out of one hundred turns of a 5000-KW excitation system will
result in approximately 100-KWs higher loss at full load.

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Higher field currents result in higher

operating temperature.

Even though the volts/amp (V/A) field temperatures instrumentation will indicate lower
operating temperatures (this is a result of the instrumentation algorithm used to calculate
field temperature assuming a constant field resistance), the higher field currents required to
maintain a given load will result in an increase in (I2R) loss for the entire rotor winding.

Because shorted-turns result in higher field current when operating at a given load, the hot-
spot winding temperature in coils without shorted-turns are higher.

Winding temperature rise above cold gas is proportional to I2. Two turns shorted out of 100
turns will result in a 4% higher hot-spot rise over cold gas temperature. The table below is an
example for one specific load.

No turn shorts 2% shorted-turns 10% shorted-turns

Cold Gas 46.0 C 46.0 C 46.0 C

Hot Spot
84.0 C 87.5 C 101.6 C
Rise
Hot Spot 130.0 C 133.5 C 147.6 C

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Decreased power generating efficiency.

The increase in field current and cooling requirements over what would be required to
produce the same amount of energy with a rotor with no shorted turns will reduce the overall
power generating efficiency of the unit.

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Online and At-speed Testing

Generatortech Rotor Winding Shorted Turn Flux Probe testing is performed while your
generator is online and at-speed. See the table below for the advantages:

Compare Testing Methods

Detects
Locations Thermal
Technique of turns?
Sensitive? Quantitative?
and Speed
Dependan
 t Shorts?
OFFLINE
TESTS
Rotor Impedance Yes- speed,
No Low No
Test voltage
Pole/Coil/Turn
Yes High Yes No
Voltage Drop Test
Search Coil Slot
Flux Distribution Yes High No No
Test
ONLINE
TESTS
V/A
No Low No Maybe
Measurement
Generatortec
h Flux Probe YES HIGH YES YES
Test

Air-gap Flux Probe Data

The Generatortech 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.
 Figure 1: Field Nomenclature & Stationary Search Coil - 6 coils per pole

Figure 2. Sample analysis graph with no-load data and field nomenclature
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.

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ample Data and Analysis Discussion

Below is test data from a 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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Figure4: Low/Intermediate Load with Shorted Turn Pole B-Coil 6

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Figure 5: High/Intermediate Load with Shorted Turns Pole A-Coil 4

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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.

All figures above show test data from the same unit. Note that the zero-crossings 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 between 5 and 10
sets of test data (depending on the unit's number of coils) 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.

Test data recorded using a 32 bit "Y" axis resolution (65,536 points) analog to digital (A/D)
computer board can produce very descriptive and quantitative data reductions. 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.

The three figures below are examples of computer analysis displays of a generator at a low
intermediate load approximately 25%. With this data in digital form, the computer can
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.
 Lead Slots Data Comparison

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Magnified Lead Slots Data Comparison

 Signature Analysis (25% Load)

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The figures below are graphs of quantitative voltage spike amplitudes of all the coils for the
generator loads in the above figures 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.
 Signature Analysis (70% Load)

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Air-gap Flux Probe Data Testing Animation

 Real Data Animation from No-Load to Full Load

This animation displays real data collected from a generator while running the machine from
no-load up to full load. The flux density zero-crossing (green line) moves from the quadrature
axis to the leading # 1 coil slot. Note the use of negative MVARS (decreasing field current) in
the last load point in order to move the flux density zero-crossing over the #1 lead slot). The
maximum sensitivity for detecting turn-shorts in coils corresponds with the position of the
flux density zero-crossing. For example, the maximum sensitivity for detecting shorted turns
in Coil #5 is found in the load point data whose flux density zero-crossing aligns with the lead
slot of Coil #5.

The figure below 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.
 Technical Considerations
Operating with Turn Shorts

Although isolated shorted turns are undesirable, their existence in a rotor winding does not
necessarily indicate a cancerous condition. Generatortech estimates 50% of the rotors in
operation may have one or more shorted turns. Rotor windings on new generators may have
one or more shorted turns after a few stop-start cycles. If the shorted turns are not
significantly affecting satisfactory operating conditions, no corrective actions should be taken.
Periodically monitoring for shorted turns will help establish whether new turn shorts are
developing and when corrective action should be taken.

No Such Thing as Partial Shorted Turns

Partial turn shorts can not exist for long. The very high temperatures generated at a small
spot will cause copper melting and a low resistance spot weld. The low resistance short will
completely short out one turn. Test data which calculates a partial shorted-turn condition are,
therefore, not correct. They are defining a limit in the test sensitivity. Engineering judgment
must be applied to estimate the integer number of turns shorted. Start-stop cycles have
resulted in healing shorted turns due to slight relative movements of the turns. However, the
chances are high that the next start-stop cycle will reproduce the shorted turns.

More on Thermal Sensitivity Rotor Unbalance

Slots with shorted turns operate at lower temperatures than slots without shorted turns. The
I2R losses are lower, but the cooling circuits remain the same. The rotor temperature gradient
to cause bows will be a function of the number of shorts and their location. Shorted turns in
coils near the quadrature axis will have little effect on thermal sensitivity balance because the
effected slots are 180 degrees apart. Shorted turns in the small coils 1, 2 and 3 on one pole
and not the other pole will have a greater effect in causing rotor unbalance problems.

Generator Electrical Losses from Shorted Turns

When shorted turns occur, higher field current is required for a specific load. The amp turn
relationship: AS = ANTN/TS. The field winding loss for a specific load will increase by the same
ratio (TS/TN). This can be calculated from the winding I2R loss formula. "R" is lower by TS/TN,
but "I2" is increased by (TN/TS)2. Two turns shorted out of one hundred turns will result in a
4% higher hot spot rise over cold gas. The table below is an example for one specific load.

No turn shorts 2% shorted-turns 10% shorted-turns

Cold Gas 46.0 C 46.0 C 46.0 C

Hot Spot
Rise
84.0 C 87.5 C 101.6 C
Hot Spot 130.0 C 133.5 C 147.6 C

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Setting Up a Shorted-Turn Condition

Monitoring Program
When planning the installation of permanent probes, the following advance planning subjects
should be addressed.

Critical machine dimensions such as rotor outer diameter (O.D.), retaining ring O.D., and
stator core I.D. need to be supplied to Generatortech so the flux probe can be manufactured
before assembly. Generatortech will provide a drawing showing which dimensions must be
supplied. If desired, Generatortech personnel will take the dimensions.

Magnetic wedges in the rotor coil slots reduce the air-gap slot leakage flux signal. Thus,
shorted turn detection sensitivity is reduced in these slots. If plans are being made to
assemble an air-gap probe, extra effort and possibly cost should be expended to ensure that
all wedges in the leading slots at the axial position of the flux probe are non-magnetic. On
some fields, this may require purchasing 2 to 4 non-magnetic wedges from the Original
Equipment Manufacturer. The wedges would be used to replace the magnetic wedges near
the turbine end in the slots leading the pole.

Discussions with Generatortech should be made early in the planning stages.

he Data acquisition & Analysis Program

Generatortech provides a Windows based program that combines data acquisition with the
display and analysis of rotor shorted turns. The system uses a high-speed 32-bit data
acquisition board to record the flux probe waveforms. The program provides an oscilloscope-
like display while recording the data. The waveform can be analyzed immediately with
Generatortech's software. The program automatically identifies and labels the waveform
features and measures the appropriate values to provide estimates of turn shorts.

Below is the raw data from a flux probe.

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Generatortech's Acquisition and Analysis Program has been designed to quickly and easily
acquire and save data from flux probes. Ease of use was the most important guiding principle
behind the design of the program. Since data collection for shorted-turn detection may be
separated by as much as six months for a single generator, the program was designed to
minimize the need for the user to relearn the program by keeping the interface as simple as
possible. The program is extremely intuative for selecting settings, opening and saving data
files, and acquiring and analyzing data.

In addition, all user settings are saved when exiting the program and are reloaded when the
program is restarted. Therefore, after the initial setup, the process of acquiring and saving
data is reduced to a few simple steps. Acquiring and saving data for each load point is quick
and easy.

Case Studies
Generatortech, Inc. has extensive experience in analyzing rotor winding shorted turns. Since
1989, over 4000 Generatortech flux probes have been installed in generators worldwide. We
have a large and growing database of test data on these units. Many generators with shorted
turns detected using our equipment have been taken apart during this time period and we
have been gratified to have had our shorted turn predictions verifed.

This section provides a look at a few case studies that forcefully make the case for flux probe
monitoring of your rotors. If you are responsible for making maintainance decisions for your
generator sets, you owe it to yourself to arm yourself with the only tool that can quickly and
accurately assess the condition of your rotor's insulation system before coming off-line.

While off-line tests are valuable, they can not detect speed-dependent shorted turns (shorts
that only develop when the rotor is at rated speed). Tests in balance-pits, with our
equipment, has confirmed the presence of speed-dependent shorted turns in a number of
cases. These tests allowed the service companies to repair the speed-dependent shorted
turns at their facility before shipping the rotors back to their customers, saving enormous
time and expense.

Case 1:
Coils 6 and 7 Completely Shorted Out of Two-Pole Rotor

This case presents a two-pole rotor with 7 coils/pole that has two coils completely shorted out
of the field winding circuit. The top turns of coils 6 and 7 on one pole initially formed a partial
short across a blocking wedge that created enough heat to burn through the retaining ring
insulation and allowed the top turns of coil 6 and 7 to form a short through the retaining ring
itself (see photo).

Coils 6 and 7 shorted out a blocking wedge (short circuit went

through retaining ring)
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Waveform shows both Coils 6 and 7 completely shorted out of Pole A

Single Turn Short in a Four-Pole Rotor

This case presents a four-pole rotor with a single turn short. The shorted turn is in Coil 2 of
Pole B. Coil 2 has seven total turns, so 1 turn short represents a 14% decrease in amp-turns
produced by this coil. The shorted turn is obvious in the waveform (below) and the
quantative analysis indicated one turn short in Coil 2-Pole B. A turn-drop test performed
when the rotor was pulled from the generator confirmed that a short existed between the
second and third turns of Coil 2 in Pole B. Since the generator was able to maintain full load
even with this shorted turn condition, no repairs were made at that time, despite the
recommendation of the OEM. This decision was made, in part, because of the ability to
monitor the shorted turn condition of the rotor while the unit remained on-line using
Generatortech's flux probe and analysis equipment. This case illustrates the cost-savings that
can be realized when unnecessary repairs can be eliminated or deferred by relying on
accurate shorted turn monitoring equipment.
Four Pole Example - One turn short in Pole B - Coil 2