CONDITION MONITORING TESTS ON HYDRO/TURBO GENERATORS AND LARGE AC MOTORS K.

Mallikarjunappa Central Power Research Institute Bangalore

CONDITION MONITORING TESTS ON HYDRO/TURBO GENERATORS AND LARGE AC MOTORS

* GENERATORS - unit rating up to 500 MW rated output voltage up to 30 kV * MOTORS unit rating up to 40 MW rated terminal voltage up to 15 kV

* Reliability and life * Reliability and life

* Stator winding * Stator winding * Stator core * Stator core * Rotor winding * Rotor winding

INSULATION
Operational reliability depends to a large extent on the condition of the insulation system Insulation is the weakest link Any unexpected failure (forced outage) in generating stations & process industries disrupt the system & cause heavy financial losses Majority of failures have been attributed to the insulation failures
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LIFE LIMITING FEATURES

Stator insulation Stator winding slot & end winding portions Tightness of stator bars in slots Stator core tightness & insulation Stator end winding bracing High levels of mechanical vibrations Frequent starts & stops Rotor winding wedging system & end winding portions Rotor end ring ( cracking, deformation ) Rotor winding insulation

STATOR INSULATION - composite type (i) Mica (ii) Glass fabric or cellulose paper (iii) Resin [Synthetic, Non-synthetic]

STRESSES ACTING
Stator winding is subjected to a combination * Thermal . High operating temp. during normal & abnormal
conditions

* Electrical. Over Voltages during transient conditions * Mechanical. High levels of mechanical Vibrations * Environmental. Moisture, oil, dust, contaminants

Thermal stress -

Delamination, tape separation, embrittlement, strand separation, girth cracking. Partial discharges.

Electrical stress - Cumulative electrochemical effects of Mechanical stress - Loosening of wedges & end winding blocks,
abrasion of the insulation - Erosion of stress grading paint & corona shielding paint

Coil

Corona shielding coating

Stress grading coating

Core
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Environmental stress - Render stress grading coating ineffective. - Electrical tracking. Slot discharges End winding discharges | * Lead to rapid failure. |

CONDITION ASSESSMENT PROGRAMME

# Consists of the following steps
Collection of the historical data Visual inspection & examination Condition monitoring tests

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HISORICAL DATA
# Can indicate problems which are generic/developed due to ageing
Age of the machine Running hours Number of starts & stops Load levels Overloading Major electrical disturbances and faults Vibration & Temperature abnormality Record of repair and replacement of components etc.

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VISUAL INSPECTION & EXAMINATION

Visible symptoms of deterioration Mechanical damage to stator bars & end winding, migration of edges Deformation of the end winding sections

Deterioration due to thermal effects .. Embrittlement, change in colour Corona damage & electrical tracking.. White/brown powdering
Loose end winding blocks, ties, lashing Deposit of oil, dirt. moisture ingress, salt etc. Powdering due to abrasion Loose core laminations Core damage due to surface discharge Change in colour of core surface due to hot spots Abrasion of the slip ring and the like.

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CONDITION MONITORING (DIAGNOSTIC) TESTS

# Conducted to * Assess state, condition & extent of deterioration *Assess trend in ageing Data logged enable to initiate appropriate remedial measures to prevent forced outages > Service life could be extended

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HYDRO & TURBO GENERATORS

Diagnostic tests. Stator winding
Sl. No 1 2 3 4 5 6 7 Tests Polarisation index test Tan delta & capacitance test Partial discharge test Wedge mapping DC leakage current Winding resistance measurement Surge comparison test Detection capability Index of dryness,cleanliness Dielectric losses Incipient faults, slot & end winding discharges Loose wedges & Loose stator bars Discontinuities & cracks Loose or bad conductor joints Inter turn faults

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Stator core

* ELCID Test

Imperfections & hot spots in the core

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Rotor winding
* Dominating stresses
> Thermal & mechanical Tests IR/PI Conductor resistance Winding impedance Recurring surge test Detection capability Index of dryness, cleanliness. Loose or bad joints Inter turn shorts in poles Intern turn & earth faults

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IR Measurement : - Reflects surface condition of the insulation - Indicates surface contamination & moisture content - PI is used as an index of dryness. PI = 2 R Y Neutral B _ Measuring connection of stator winding
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Line

Test voltage

DC Leakage current measurement

DC voltage is increased in steps. At each step, voltage is maintained constant for a predetermined time interval (100 sec.) and current is recorded Max. test voltage as per guidelines Plot current verses test voltage

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Micro amps.

(3) (2)

(2) (1)

DC voltage (kV) (1) - Solid homogeneous insulation in good dry condition (2) - Faulty insulation due to dirt & oil, ageing, mechanical damage or tape separation (2a) - Faulty insulation - step ladder curve due to internal voids & ionisation (3) - Insulation in wet condition

Typical curves obtained when testing insulation of large rotating machinery. Vdc = 1.6 x (AC test voltage level) 1.5 Vph
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Tan delta Test:

Concept Of Tan delta

Represents dielectric losses

Insulation between two electrodes Treated as Capacitor HV

Electrodes

INSULATION

LV

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In a Perfect Capacitor current leads the voltage by 900

Perfect Capacitor

Phasor Diagram

Cp

900 V
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Practically Phase angle is < 900 Loss angle Phase angle

Due to dielectric losses I

Ic

Ir V

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Lossy Dielectric

Ic

Ir Ic

Cos = Ir / I = Sin

Cp Rp

Tan = Ir/Ic

Ir

Phasor diagram
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Measurement of Tan delta :

High Voltage Schering Bridge
H.V.

Rp +(1/jCp)

Z1

Rx

Cx

Cn

Z2 CRO

Z3

R4 R3

C4

Z4

L.V

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Tan measurement procedure : * Single phase testing transformer of suitable KVA rating * Equipment under test needs to be disconnected from the system * Tan kit to be grounded to the system grounding and test voltage is raised in steps upto the rated phase voltage Generator Stator Motor R Y B HV

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Tan - Voltage characteristic.

Test voltage is raised in steps up to a maximum of rated service voltage. Tan is measured at each voltage level. Plot Tan v/s Voltage. Wet & contaminated Deteriorated Gaseous loss Solid loss 0 Voltage
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Tan

Sound

Test parameters: - Tan delta & capacitance at 0.2 VL - Tan delta tip-up tan delta Vph - tan delta (0.2VL) 2 Cap. Vph - Cap. (0.2VL) Cap. (0.2VL) * Changes in the above quantities with machine age * Statistical variation of these quantities of similar machines.

- Capacitance tip-up

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Limiting values of tan delta for new coils/new windings

Rated line voltage VL (kV) tan at 0.2 VL 6.6 0.04 0.02 0.03 0.03 0.04 0.02 0.03 0.03 0.04 Mica with synthetic bond tan Maximum tan per 0.2 VL 0.006 0.005 0.005 0.006 0.006 0.005 0.005 0.006 0.005 tan at 0.2 VL 0.05 0.04 0.03 0.05 0.05 0.05 0.03 0.05 Mica with nonsynthetic bond tan

11.0

0.003 0.0025 0.0025 0.003 0.003 0.0025 0.0025 0.003 0.0025

0.006 0.003 0.0025 0.006 0.006 0.003 0.0025 0.006

Maximum tan per 0.2 VL 0.016 0.006 0.005 0.012 0.016 0.006 0.005 0.012

a) BEAMA REM 500, 1969 (b) Balcombe and Statt (CEGB), 1973 (c) CENELEC, 1974 a) BEAMA REM 500, 1969 (b) Balcombe and Statt (CEGB), 1973 (c) CENELEC, 1974 (d) ESI Standard 44-5, 1987 (e) VDE - -0530 (d) ESI Standard 44-5, 1987 (e) VDE 0530
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Partial discharge Test Partial discharges

# PD occur due to the presence of # PD occur due to the presence of * voids, conducting particles, de-lamination * voids, conducting particles, de-lamination * PD are deleterious to the insulation * PD are deleterious to the insulation * Cause chemical & mechanical destruction of the surrounding * Cause chemical & mechanical destruction of the surrounding insulation insulation

tan delta

Gaseous loss Material loss

Voltage
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Concept of Partial discharges Concept of Partial discharges

- Discharge process in which the gap between two electrodes is only partially bridged. HV
Void Conductor Insulation

* Cause chemical & mechanical destruction of the surrounding medium & hence premature failure.

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Effects of PD PD can give rise to

Ozone Nascent oxygen - strong oxidising agents Nitric acid in presence of moisture Oxalic acid in polymeric insulation Mechanical erosion due to ion bombardment Intense heat in the discharge channel Power loss

* PD cause chemical & mechanical destruction of adjacent materials.

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HV

3 2 1 Dielectric

1 - Internal partial discharge (Cavity discharge) 2 - Internal partial discharge ( between metallic & dielectric surfaces) 3 - Surface discharge (outside the insulation)

Representation of a partially defective dielectric

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HV HV

PARTIAL DISCHARGE TEST PARTIAL DISCHARGE TEST IEC-60270 IEC-60270

Cc Cx Test object Cb Ec

Z1

Detection impedance

Discharge detector

G G

Cb - Blocking capacitor
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Basic Partial Discharge Detection Circuit

ANALYSIS OF PD DATA
* PD are highly stochastic in nature

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Calibration
Effected by injecting pulses of known charge contents. Calibrating pulse -- PD pulse - Magnitude & time characteristics must be comparable. Rise time -- 50 - 100 nano sec. PD magnitude, q = eq. Cq
V 0 Calibrating pulse

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PARTIAL DISCHARGE TEST

* Found to be effective * Capable of revealing incipient faults * By analysing the PD data it is possible to identify type of fault in the machine

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Partial discharge test continued.

Hydro & Turbo generators
* Internal discharges .. Occur in voids / cavities * Surface discharges Highly deleterious > Slot discharges .. Between coil surface & iron core > End winding discharges .. Junctions of corona shielding & Stress control coatings

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PD Analysis
Continued..

Need to be analysed statistically PD Quantities

* Magnitude (q) * Number density (n) * Polarity * Phase angle of occurrence () * Quadratic rate

# Distribution profiles
* Magnitude - Number density distribution (q-n) * Magnitude - Phase angle distribution (q- ) * Number density - Phase angle distribution (n-) and * 3D patterns of ( q-n- ) # Finger prints and temporal changes can be used to characterize defects

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Comparison of PD patterns
Int. Void Void facing the HV electrode Void facing the grounded electrode

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Comparison of PD Patterns
Int. Void Void facing the HV electrode Void facing the grounded electrode

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On-line Condition monitoring of Turbo & Hydro On-line Condition monitoring of Turbo & Hydro Generators Using P.D Testing Generators Using P.D Testing
Deterioration mechanisms result in P.Ds caused by Deterioration mechanisms result in P.Ds caused by * Voids in the Insulation * Voids in the Insulation * Electrical tracking on the end windings * Electrical tracking on the end windings * Sparking between the stator core and loose stator coils * Sparking between the stator core and loose stator coils Insulation deterioration can be detected by monitoring P.Ds Insulation deterioration can be detected by monitoring P.Ds
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How to detect PD in Generators ? How to detect PD in Generators ? Three Types of PD sensors Three Types of PD sensors * Capacitive couplers * Capacitive couplers * HFCT * HFCT * Stator slot couplers * Stator slot couplers

Sensors are permanently installed in the stator Sensors are permanently installed in the stator winding during planned outage or during winding during planned outage or during manufacturing stage. manufacturing stage.
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1. Capacitive couplers (80 pF -- 1000 pF) 1. Capacitive couplers (80 pF 1000 pF) Coupled to the stator winding at Coupled to the stator winding at * Generator bus bars. * Generator bus bars. * Stator winding connecting rings at the * Stator winding connecting rings at the overhang portions overhang portions * Can be retrofitted to old generators. * Can be retrofitted to old generators.

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2. HF CTs :- Can be incorporated at 2. HF CTs :- Can be incorporated at Neutral end Neutral end Frequency range 0.3 -- 100 MHz Frequency range 0.3 100 MHz can be retrofitted to old generator can be retrofitted to old generator

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3. SSC :3. SSC :SSC is a broad band antenna (UHF Band) SSC is a broad band antenna (UHF Band) SSCs are installed under the wedges in the stator SSCs are installed under the wedges in the stator Coaxial cables are routed to a point outside the Coaxial cables are routed to a point outside the generator. generator.

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Interpretation of PD quantities
* Still a challenging task * Often subjective * Depends on experience and expertise * Subject of intense research

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WEDGE TIGHTNESS TEST

> Important test specified for RLA studies on Generators
# Stator wedges may be slackened due to * Shrinkage of slot packing materials * High mechanical stresses * Vibration ^ Loose wedges cause * Loosening of stator bars * Excessive vibrations * Erosion of corona shielding & stress grading coatings * Abrasion of insulation

$ EVENTUALLY LEAD TO FAILURE OF STATOR WINDING.

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ELECTRONIC WEDGE TIGHTNESS EVALUATION

# Electronic method
* Sophisticated * Provides map of wedge tightness * Data can be stored for accurate trending of WT data

* Hand tapping method with a hammer

> Crude method > Highly subjective > No data can be generated > Trend analysis is not possible.

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WTD Methodology * Each wedge is tapped automatically by a magnetic hammer > Tapping force is constant * Accelerometer picks up the signals * Signals are processed & stored * Software provides a map of relative tightness of the wedges.

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STATOR CORE STATOR CORE

Made up of thousands of thin steel Laminations Made up of thousands of thin steel Laminations (typically 0.5 mm) (typically 0.5 mm) Laminations are coated with a thin layer of electrical insulation Laminations are coated with a thin layer of electrical insulation to prevent eddy currents. to prevent eddy currents. Laminations are frequently shorted together at the back by Laminations are frequently shorted together at the back by support bars support bars

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DEGRADING FACTORS DEGRADING FACTORS

* Mechanical damage to the stator bore surface or top slot walls * Mechanical damage to the stator bore surface or top slot walls * Vibrations in the core may cause abrasion of inter laminar * Vibrations in the core may cause abrasion of inter laminar insulation & short circuits insulation & short circuits * Shorts between adjacent laminations cause eddy currents to be * Shorts between adjacent laminations cause eddy currents to be induced by the rotating magnetic flux. induced by the rotating magnetic flux. * These currents can produce dangerous local overheating/hotspots * These currents can produce dangerous local overheating/hotspots in the damaged areas in the damaged areas * In extreme cases sufficient heat is generated to locally melt small * In extreme cases sufficient heat is generated to locally melt small parts of the core parts of the core * Hot spots may lead to premature failure of stator winding * Hot spots may lead to premature failure of stator winding insulation insulation
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DEGRADING FACTORS

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Vibrations

CPRI

Erosion of corona shielding coating

Erosion of stress control coating

Abrasion, fretting of core laminations

Slot Discharges

End winding Discharges

Short circuiting of adjacent laminations

* Pittings on stator
bar insulation * Fusion of core laminations (short circuiting)

* Damage to core end portion * fusion of core lamination

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CPRI

Eddy currents induced circulate (Hot spots) Local burn out of the core Extensive damage to the core

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CPRI

TESTING OF STATOR CORE TESTING OF STATOR CORE

Conventional Test on Core * Core loop test

- to detect hotspots in the core loop Cable

High current source

Water Rheostat

Core CT Voltmeter

Schematic diagram of Core Loop Test

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Core loop test . continued Core loop test . continued

CPRI

* A no. of turns of heavy cable is wrapped toroidally around the core & frame. * Very high AC current (hundreds of amps.) sufficient to produce flux density almost equal to operating level. * Core gets heated up. * Temp. is measured at several points on the core surface. * Infra red scanning to detect hotspots.
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ELCID TEST ELCID TEST

* Induce only about 4 % of the flux in the core by passing an AC * Induce only about 4 % of the flux in the core by passing an AC current (5 --15 Amps) through a excitation winding looped current (5 15 Amps) through a excitation winding looped toroidally around the stator frame. toroidally around the stator frame. Small pick coil senses the fault current induced at the defective Small pick coil senses the fault current induced at the defective core section core section > Excitation current > Excitation current * Single turn voltage of the generator,Vpp * Single turn voltage of the generator,V Vpp= V ph//((ktpp) where V ph=Phase voltage V = V ph kt ) where V ph=Phase voltage k = pitch factor,0.92 k = pitch factor,0.92 ttp = Number stator bars per p = Number stator bars per phase phase # For ELCID test, single turn voltage=4%Vpp # For ELCID test, single turn voltage=4%V

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Schematic diagram of ELCID test ing

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ELCID Test on 27Mw Hydro generator

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A view of ELCID test set up

A view of ELCID testing in progress

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TYPICAL ELCID DATA TYPICAL ELCID DATA

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DEFECTIVE CORE DEFECTIVE CORE

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Rotor winding

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Rotor Winding (Turbo generator)

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ROTOR WINDING ROTOR WINDING

* Dominating stresses * Dominating stresses * Thermal * Thermal * Mechanical * Mechanical

TESTS TESTS
* IR/PI * IR/PI Deterioration, dampness, Contamination (cleanliness) Deterioration, dampness, Contamination (cleanliness) Interturn faults Interturn faults Resistance Bad conductor joints Resistance Bad conductor joints
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* Field Impedance * Field Impedance * Conductor * Conductor

SURGE TEST SURGE TEST

* Rotor winding -- RLC circuit * Rotor winding -- RLC circuit * LV Surge (( 250 V) is applied * LV Surge 250 V) is applied * Resultant waveform is recorded * Resultant waveform is recorded * Both the waveforms are super imposed * Both the waveforms are super imposed * Waveform coincide each other and appear as a single * Waveform coincide each other and appear as a single waveform if there is no interturn fault waveform if there is no interturn fault
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CASE STUDIES
1) 11 kV, 144 MVA Hydro generator Stator winding:
IR = 700 M tan = 0.87% = 0.29% T = 0.36% C IDE = 1.01 J/pF/cycle Vi = 5.3 kV Qc = 3600 pC

Assessment: * Low dielectric losses * Low void content * Insulation condition of stator winding healthy

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Rotor winding
Pole impedance Varied from 4.82 to 10.67

Visual inspection revealed migration of turn insulation of 02Nos. of poles

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Migration of turn insulation at the top of the poles

Migration of turn insulation

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Migration of turn insulation at the bottom of pole

Migration of turn insulation

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13.8kV 100Mw Hydro Generators

* Operating in a Hydro power station Age varying from 19 years to 26 years Conducted Tan delta & PD tests

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PD Patterns

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13.8kV 100Mw Hydro Generators

Generator G1 G2 G3 G4 G5 G6 G7 G8 Tan (%) 2.81 1.40 1.30 1.4 1.48 1.14 1.89 1.25 T (%) 0.68 0.18 0.31 0.37 0.29 0.17 0.14 0.14 C (%) 1.78 0.41 0.76 0.93 0.74 0.27 0.28 0.26 PD mag.(pC) 5300 7363 11,629 11,755 9,385 860 11,502 8,943 Vi (kV) 3.96 3.22 3.31 3.21 3.26 3.96 3.25 3.44

* Low dielectric losses * Low void content * Low dielectric losses * Low void content * Stator windings are in healthy condition * Stator windings are in healthy condition

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11kV, 115Mw Hydro Generators

Salal Power Station
Generator 1 2 3 4 5 6 PI 4.15 2.54 4.84 3.74 2.69 4.21 Tan delta (%) 0.41 1.02 1.049 0.88 0.925 0.876 T (%) 0.23 0.18 0.058 0.021 0.035 0.0315 C (%) 0.22 0.19 0.025 0.053 0.064 0,0844 PD Level (pC) 1100 2500 2000 4000 1500 4000 DIV (kV) 3.21 4.0 4.0 4.4 3.96 4.4

* Low dielectric losses * Low void content * Low dielectric losses * Low void content * Stator windings are in healthy condition * Stator windings are in healthy condition

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2) 11kV, 7.2Mw Turbo generator

18 years old class-F machine installed in a Polyfibres industry

PI = 2.9 tan = 1.85% = 0.22% T C = 0.40% IDE = 0.92 J/pF/cycle Vi = 4.8 kV Qc ~ 40,000 pC. Discharges of very high magnitude in R & Y phase sections

* Slot / end winding discharges were suspected.

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11kV, 7.2Mw Turbo generator

continued..

Decision was taken to visually inspect the stator winding and Conduct inductive probe test to locate the sites slot/end winding discharges Results of visual inspection & inductive probe test Presence of white powder at the end winding regions of several bars Visible sparking was observed at the end winding regions two bars bearing No.2 & 22 ( Line end of R & Y phases ) Deposits of white powder were found both on exciter & turbine ends. Deposits of white powder are a symptoms of end winding discharges Inductive probe test indicated presence of slot discharges900mV Recommended for re-wedging.
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11kV, 7.2Mw Turbo generator

continued..

Company accepted the recommendation & initiated action Tests were conducted after re-wedging with side packing materials & varnishing

PI = 2.8 tan = 0.93% = 0.087% T = 0.26% C IDE = 0.21 J/pF/cycle Vi = No discharges up to 6.35 kV

Generator is in healthy condition.

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1). 11kV, 2700kW Synchronous motor 1). 11kV, 2700kW Synchronous motor * Class --F, 10 years old * Class F, 10 years old * Fertilizer Company * Fertilizer Company tan tan T T C C IDE IDE Vi Vi = 2.51% = 2.51% = 2.64% = 2.64% = 9.28% = 9.28% = 6.96 J/pF/cycle = 6.96 J/pF/cycle = 3 kV = 3 kV

* Indicate high level of deterioration * Indicate high level of deterioration # Recommended for rewinding # Recommended for rewinding # Failed after a year # Failed after a year
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2). 6.6kV, 5.1MW Synchronous motor 2). 6.6kV, 5.1MW Synchronous motor * Class B, 12 years old * Class B, 12 years old * Petrochemical Plant * Petrochemical Plant T T C C Vi Vi = 3.38% = 3.38% = 11.6% = 11.6% = 2.10 kV = 2.10 kV

* High value * High value

* DLA pattern indicated presence of end winding discharges * DLA pattern indicated presence of end winding discharges (unstable pattern) (unstable pattern) # Recommended for rewinding # Recommended for rewinding # Failed after two months # Failed after two months

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3). 6.6kV, 1750KW, Induction motor 3). 6.6kV, 1750KW, Induction motor * Class --F, 1 year old * Class F, 1 year old * Cement Industry * Cement Industry IR IR tan tan T T C C IDE IDE = 700 M = 700 M = 2.81% = 2.81% = 0.39% = 0.39% = 1.29% = 1.29% = 0.175 J/pF/cycle = 0.175 J/pF/cycle

* Due to intense slot or end-winding discharges * Due to intense slot or end-winding discharges # loop trace distorted & unstable # loop trace distorted & unstable # wavy unstable pattern appeared beyond 2kV # wavy unstable pattern appeared beyond 2kV * Failed after a week * Failed after a week
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CONCLUSIONS
Condition monitoring tests are Non-destructive type * Defective components can be identified * Premature failures can be avoided * State & condition of the equipment can be assessed * Impending problems or deteriorating factors can be detected Systematic diagnosis programme and periodic monitoring enable life extension

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THANK YOU

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11kV/220kV, 43.33MVA Generator Transformers (18 Nos.) GT1

Insulation section HV/LV+G(R) LV/HV+G(R) HV/LV(R) HV/LV+G(Y) LV/HV+G(Y) HV/LV(Y) HV/LV+G(B) LV/HV+G(B) IR 1680 2100 3580 6200 9750 6400 4580 6000 PI 2.19 2.07 1.76 1.56 1.57 1.51 1.81 1.83 Tan delta (%) 0.367 0.357 0.362 0.36 0.353 0.358 0.338 0.341 <2.0 2250 2.54 3000 Moisture level (%) 3.18 PD Level (pC) 2400

HV/LV(B)

9720

1.8

0.314 85