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DNV KEMA sERVING THE ENERGY INDusTRY Non-destructive testing & plant diagnostics

Diagnostics and testing of rotating electrical machines

PREPARE AND PREVENT

02 ENERGY Non-destructive testing & plant diagnostics

PREPARE AND PREVENT


Diagnostics and testing of rotating electrical machines Rotating machines are of vital importance to many business processes. As the demand for energy continues to grow, operational continuity is increasingly important. The failure of rotating machinery used in energy production, waste processing and other industrial processes not only has nancial and operational consequences for the owners, but in many cases also has implications for the community at large. DNV KEMA Energy & Sustainability possesses enormous specialist expertise, which is made available to help clients keep their vital processes running.
ResPOnsIBLe Use OF aGInG maCHInes

Being vital to many industrial processes, rotating machines are designed to operate reliably for years on end. However, as time goes by, attention inevitably is focused on the condition of aging machines and how much longer they can be expected to go on providing problem-free service. With a wide range of diagnostic techniques at its disposal, DNV KEMA can help you minimize the operating and financial cost of finding answers. Our advice will enable you to identify the most cost-effective and responsible maintenance strategy and operational approach, now and in the future. The need to manage costs makes it sensible to consider whether rotating machines can remain in service longer without undue outage risk or excessive expenditure on maintenance.

After all, the serviceability of a component depends not only on its age, but also on the way it is operated and maintained, and what has happened to it in the past. DNV KEMA can provide answers to the questions that you are liable to face, such as: What condition is our machinery actually in? Can we make even better use of our rotating machinery? How much longer can our machinery remain in service? Can we reasonably postpone capital expenditure? Is it worthwhile repairing our machinery, or should we replace it? How big a risk would we be taking if we took no action yet? What was the cause of the damage our machine has unexpectedly suffered, and who is responsible?

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It is not always easy to give answers to such questions. A rotating machine is, after all, merely part of a large and complex process. It is expected to simply go on doing its job, and analyzing its condition is not part of your core activities. Although most companies that operate rotating machinery are reasonably knowledgeable about the working of their assets, precise condition determination and residual service life assessment are the work of specialists. Specialists for whom the testing and inspection of machinery are everyday tasks and who have an armory of diagnostic techniques at their disposal. Specialists who bring many years of experience to the diagnosis of your installation and who are able to consider your machinery from an impartial perspective.

Specialists that DNV KEMA can deploy on your behalf. At DNV KEMA, we have the knowledge, the methodological expertise and tools to provide you with the backup and support that you need to maximize operational efficiency and reliability. Now and in the future.
DesIGn

DNV KEMA can help you to obtain exactly the right machine for your company or process. A supplier is responsible for delivering products and services that meet your specified requirements. It is therefore important that you specify your requirements accurately. Well-formulated DNV KEMA (S-)specifications provide a basis for the assessment of a suppliers design. Good specifications are the starting point for a sound design, which is essential for obtaining a machine that performs optimally throughout its service life.
ManUFaCTURe

During manufacture, a number of topics are of particular importance: the selection of materials and the actual process of manufacture and the mechanisms with which you, as the (prospective) owner, can obtain assurance regarding the quality of the finished machine. DNV KEMA can support you during manufacture by providing ongoing quality control, by witnessing the acceptance tests at the factory and on site, and by supervising the commissioning.

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Quality control: checking the manufacturing process by inspection and testing. Various components are tested during manufacture. The manufacturers progress, quality assurance measures and results are also assessed. Tests (FAT and SAT): DNV KEMA performs its own tests or witnesses testing by others to check conformance to the design specifications. During factory acceptance testing (FAT), type tests and routine tests are performed to verify that the rotating machine has been built in accordance with the specifications. During site acceptance testing (SAT), the quality of the delivered installation is checked to ascertain whether it fullfils the applicable requirements. Commissioning: once all the separate components have been installed and tested, DNV KEMA will witness and assess testing of the complete installation under various normal and/or extreme operating scenarios, defined by consultation.

OPeRaTIOns

FRom design to decommissioning


The life cycle of any machine may be divided into the following phases: Design Manufacture Operation Conservation Decommissioning

Our approach to condition assessment and residual service life forecasting has several elements, which together provide an accurate picture of the machine as a whole. First there is the actual inspection and testing. These activities are followed by the interpretation of measured data and analysis of the existing situation. Interpretation and analysis yield an overview of the condition of the machine and its likely residual service life. Finally, there is failure analysis. In the event of unexpected problems, destructive testing of the failed component can be undertaken to ascertain the cause. As well as providing you with insight into the condition and residual service life of your machinery, we can advise you regarding the most cost-effective repair, maintenance and operating strategy. We can indicate whether it is best to take a machine out of service straight away, to make provision for replacement, or to continue running the machine normally. The diagnostic techniques that we use are selected to minimize the need to dismantle rotating machinery. Dismantling is a costly and time-consuming business, which introduces risk; as such it should be avoided except where strictly necessary. DNV KEMA uses four primary techniques for condition assessment and residual service life forecasting: Endoscopy: a visual inspection technique that enables the examination of areas that cannot be viewed with the naked eye Dielectric testing: a technique for assessing the electrical insulation of rotating machinery components

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Mechanical engineering inspections: non-destructive testing that yields information about the mechanical condition of a machine Failure analysis: analysis with a view to identifying and describing the causes and mechanisms of failure

hazardous materials is specialist work. DNV KEMA has the expertise and the professional personnel required to oversee decontamination activities and verify compliance with the applicable regulations. DNV KEMA is not associated with any supplier. Moreover, DNV KEMA has decades of experience in the diagnostic analysis and condition assessment of rotating machinery. We also have our own certified laboratories. DNV KEMA is a reliable and independent provider of technical and operational services, as well as inspection, testing and certification services. We have the expertise, facilities, technology and experience to answer all your questions about the condition and residual service life of your installation. If you wish, we can also provide you with decision-making support and advise you on the implementation of appropriate measures.

DeCOmmIssIOnInG

When a rotating machine reaches the end of its economic and technical service life, we can advise you about its decommissioning. If your installation no longer fullfils the applicable requirements, it may well require decontamination. This involves the disposal of harmful substances, such as asbestos, oil and heavy metals. The decontamination of

DNV KEMA offeRs the foLLowing seRvices


Advice Inspection Quality control Diagnostics Failure analysis (non-)destructive testing

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DNV KEMA, YOUR pARTNER IN ROTATING mACHINERY


Valuable knowledge with practical applications Systems are becoming increasingly complex. Generators are large and applied materials and techniques sophisticated. Electricity is generated in a generator, thus being the component and source of all pleasant things in life, hence, the source of todays prosperity. So no one wants to think of the situation when the generator fails to produce electricity.
GeneRaL

The generator is one of the most crucial parts of a nuclear, fossil or industrial plant. It is therefore of major importance that the generator is always in a perfect condition. They have been designed to operate for years without any problems. However, when time passes by, condition deteriorates and the chance of failure increases and forced outages are not always avoidable. DNV KEMA offers a broad range of cutting-edge techniques which can be performed within the shortest possible timeframe against minimum costs.

The results provide insight in the most cost-effective and accountable approach for operation and maintenance of the generator, now and in the future.
IndePendenT and ReLIaBLe FaILURe seRvICes

OUR seRvices incLUde


Retaining ring inspections Bump testing Honing and boresonics examinations

It never rains, but it pours. This well-known saying is true for failures in complex industrial installations, which is why it is vital to find the answers to three important questions: what caused the failure, might it happen again, and how can this be prevented? These questions lead to other more detailed questions like: has there been an accident, is it a structural fault, or is it due to negligence during the installations daily operation? Once failure has occurred, it is already too late. The remaining possibility is to evaluate. Many problems have their cause in the design phase.

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DNV KEMA begins with the analysis of both the failure and the generator itself, its mechanical and electrical properties. Apart from failure analysis in the laboratory, investigations take place on site, which might involve visual examinations, electrical or non-destructive testing. To prevent failure in the future, we might recommend changes in design, operation and maintenance. In the course of their investigations, our experts make use of every available tool and technique, including inspections, diagnosis, database references and procedural and ethical assessment. We have our own world-renowned test laboratories at our disposal, equipped with the most advanced equipment.
VIsUaL InsPeCTIOns and QUaLITY assURanCe

Inspections can be made during the manufacture of new components, during maintenance stops or failures at operating installations. Besides registering defects, our inspector will suggest solutions, giving you access to all of DNV KEMAs testing and calculation facilities and any other expertise you might require, for example the insulating quality and our knowledge of materials, composites, plastics and paint. We can carry out non-destructive tests, failure analysis, fitness for purpose analysis and remaining lifetime assessments. In order to maintain the knowledge and expertise which we have gained over the years, a team of DNV KEMAs experts are united in a so-called knowledge platform called CentRoM, which is the central organization for rotating machinery.

Problems can be prevented by means of effective quality control. It is advisable to keep a close check on quality during manufacture, repairs or construction work. DNV KEMA has over decades of experience in the technical inspection of electricity generating units, transmission systems and substations. Over the years, the DNV KEMA inspectors have gained extensive know-how concerning potential bottlenecks in the design, production and repair processes. It is possible to anticipate such bottlenecks by means of an adequate inspection program. We usually use a well-considered approved action plan, but our inspectors will base their recommendations on your approach and plans, giving you an individual custom-made service.

YoUR benefits
By preventing failures, no loss of production & no repair bills Database with info gathered over 40 years of experience in failure analysis Independent organization with objective test results recognized worldwide Clear insight in capabilities & limitations of materials & products Highly qualied staff ensures valuable support in identifying & solving your technical problem

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ROTOR DYNAmICS AND ELECTROmAGNETIC FIELDS


A powerful but dangerous combination
A rotor is exposed to a complex spectrum of forces of both mechanical origin (rotation) and electrical origin (electromagnetic fields). Furthermore, a rotor is an assembly of numerous components that have to operate in perfect balance and fully insulated from one another. The main components of a turbo generator rotor are: Rotor body Windings End winding retaining rings Rotating rectifier Each component has its own particular properties and therefore requires specialist testing and analysis.
THe GeneRaTOR ROTOR

at very high speed (typically 3,000/3,600 rpm). Furthermore, although the rotor experiences great mechanical stress and high temperatures (in some cases up to 300F/150C) while subjected to electrical voltage and current, it is expected to function in this manner for years without failure.

The rotor can be visualized as a large rotating electromagnet with north and south poles. The generator rotor represents an excellent combination of electrical, mechanical and manufacturing skills in which the field coils are well insulated, supported and ventilated in a compound structure rotating

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The three design constraints limiting the size and life of generator rotors are temperature, mechanical force and electrical insulation. Degradation of the generator field can be caused by a number of factors, including a breakdown in insulation due to time and temperature and mechanical wear. To understand the intricacies of the field winding design, we must remember that the basic function of the rotor is to produce a magnetic field of the size and shape necessary to induce the desired output voltage in the stator. The winding and components should be designed to require little maintenance during the 30 or more years of expected operation, which is the typical lifetime for a base-loaded power station.

Rewinds may be more frequent under extreme conditions such as an open ventilated gas turbine generator in a dirty environment, or frequent start/stops or load cycling. As a generator rotor ages, its insulation can be affected by temperature, mechanical wear and operating incidents. Rotor forging and other rotor components are also at risk. The most common problems occurring with generator rotors are shorted winding turns and breakdown in groundwall insulation.
ROTaTInG dIOde BRIdGe assemBLY

There are two types of excitation systems which can be employed for generators, the brushless excitation system and the static excitation system. With the brushless excitation system the exciter consists of two basic component assemblies, the exciter stationary field assembly and the exciter rotor comprising the rotating exciter armature and a rotating rectifier bridge assembly.

A tURbo geneRatoR RotoR mainLy consists of the foLLowing components


Rotor body Windings End winding retaining rings Rotating rectier

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The poles of the stationary field assembly are excited by an auxiliary winding in the generator stator via a voltage regulator. Optionally, the supply can also be provided by a pilot exciter. The three-phase current generated in the rotating armature of the main exciter is rectified via rotating diodes and conducted to the rotor winding of the turbogenerator via copper conductors in the shaft center. Basically, the diodes convert the alternating current output of the exciter generator to direct current, which is then fed to the rotor winding of the generator. DNV KEMA performs visual inspections with regard to the functioning of these rotating diodes. With a static excitation system the rotor field current to the rotating field winding of the generator is supplied via slippings.
STaTORs

The conductor bundle consists of a number of single conductors ranging from a few numbers in very small motors to more than 200 in large turbine type generators. Depending on the type of machine and rated voltage and current the conductors are connected in series or in parallel. These conductors have to be insulated due to the different voltages. This insulation is stressed, but mainly by temperature and voltage transients. A challenge on its own is the part of the winding that is outside the core: the end windings. The sole function of these windings is to guide the current from the conductors in one slot to those in another slot.

The stator of a 3-phase rotating electrical machine, regardless whether it is synchronous or asynchronous, is the most expensive part of the machine. Here the energy of the magnetic field is transferred in electrical energy or vice versa. Phyiscally, the largest part of the stator is the core that carries the magnetic flux and also holds the windings. Within these windings the conductor bundles carry the electric current that flows due to the voltage induced by the magnetic flux. The main insulation in between the conductor bundle and the core has to deal with dielectric stress, temperatrue, different thermal expansion of the core and the copper in the conductors and vibrations, and in some cases in difficult ambient conditions.

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Being built up entirely from copper and insulation materials, end windings are complex mechanical constructions that are especially vulnerable to transient over currents and suffer easily due to vibrations. Last, but not least, there is insulation material in the core itself which is necessary to avoid circulating currents between the core sheets. This material is also stressed, but mainly due to temperature.

Important questions are the quality during start-up, the speed of aging, the condition at a given moment in time and the remaining lifetime from that moment on. A number of (diagnostic) tools has been developed to furnish answers to all these questions.
GeneRaTOR COOLeRs

The cooling medium at larger generators is hydrogen (H2). The advantage of this gas is its lack of viscosity and sufficient specific heat capacity. However, an obvious disadvantage is its inflammable character. Leaks in these coolers that are built in the generator housing lead to sudden outages and costly repairs. These coolers should be checked regularly in order to reduce chances of leaking. With Eddy Current technology and combined visual inspection this can be performed quite efficiently. There is no budgetary reason not to check these during generator revisions, whereas the benefits of having early warnings can be large.

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MECHANICAL TESTING OF ROTORS AND STATORS


Safe operations with aw indications
ReTaInInG RInG InsPeCTIOns BUmP TesTInG OF sTaTOR end WIndInGs

Replacing retaining rings is quite an expensive operation, it may even cost up to EUR 1,000,000. The DNV KEMA Inspection system of Retaining Rings (KIRR) offers a perfect solution to these problems. This system detects and characterizes flaw indications in the retaining ring and will enable you to determine whether the retaining ring needs to be replaced. Furthermore, you will be able to continue monitoring newly detected flaw indications that are still acceptable to be worked with. This means that you can regularly keep an eye on the condition of the retaining rings. Initially DNV KEMA will try to obtain as much information as possible about the rings geometry and the actual access to the rotor, sometimes there is hardly any information available. The rings geometry is then first measured using an ultrasonic C-scan mapping technique. Ultrasonic crack detection is focused on the shrunk connections and wall thickness steps. The rings coating is left in place. Geometry and flaw data are then fed into a computer model. The residual life span is embedded in the analysis.

With bump testing the natural response of an end winding is measured upon excitation with a mechanical impulse (hammer). The response is fully determined by the properties and mechanical structure of the stator end winding. This principle is comparable to the excitation of piano strings by their hammers when vibrating in distinct frequencies and thus producing a tone. A relative simple method when compared with the end winding, but nevertheless the natural vibration frequencies of a complex part can be measured accurately. An acceleration transducer is mounted successively on each end winding unter test. The measured signals are fed into a data analyzer and the response frequencies and magnitudes, the so-called Power Spectrum Density (PSD), is recorded, showing the energy distribution of vibrations. An extra acceleration transducer is mounted at the hammer. The most important frequency range for analysis lies between 95 and 110 Hz. Depending on temperature resonance, modes can shift slightly during operation. Electromagnetic forces at the windings have a frequency of 100 Hz. When natural vibrations lie close to 100 Hz, resonance may occur resulting in

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high movement of the end windings and high wear, resulting in even higher vibration magnitudes et cetera, culminating in collapse. The frequency spectrum which is measured by its acceleration transducer lies in the range of 20 to 200 Hz and delivers the base spectrum that is induced in the object under test. Frequency Response Analysis is used with which the obtained frequency spectra from the end winding are divided with this base spectrum, yielding a normalized signal.
WedGes

GeneRaTOR BORe eXamInaTIOns BOReSOnICs

In order to support windings of electrical machines in the slots of rotors or stators, various wedges are used that are capable of withstanding the mechanical and electrical stresses acting on the windings during steady state and dynamic behavior of the machine. In combination with liners, blocks and other materials, they maintain the position of slot windings and end windings, without causing heavy stray currents, short-circuit currents, and without vibration of the windings. Furthermore, all these tools are capable of withstanding the high temperature stresses in the machine. It is of paramount importance that the wedges and other supporting materials do not loose their supporting capabilities during service, that these are not subject to degradation and that they remain fixed, without any space for vibration, noise generation, risk of getting loose and that under no circumstances any part may interfere with the rotation of the machinery. Any refurbishing of the machine shall include a thorough inspection and check of all winding supporting materials.

Boresonics encompasses a series of operations and examinations conducted on generator rotors with central bores through their forgings. Lessons are learned from a catastrophic event, as such is the case for the in-service practice of examining the near surface volume of material in generators with central bores. The honing process serves to remove any oxides that may have formed that would interfere with subsequent surface examinations such as visual, magnetic particle or Eddy currents. It also provides a means to remove a layer of material that may have become embrittled and subject to crack initiation. The process also produces a smooth uniform surface that resists stress concentrations. DNV KEMA has developed a field transportable horizontal honing system. This system provides surface preparation on bores from 70 to 250 mm (2.75 10 inches) in diameter, and bore lengths of up to 13.2 meters (40 feet). The system allows you to let DNV KEMA accomplish a full range of tasks associated with the required bore inspections, like: Visual examination Magnetic particle examination Eddy current examination Ultrasonic examination Follow-up services

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ELECTRIC TESTING OF ROTORS


DC-ResIsTanCe OF THe ROTOR WIndInGs

In order to detect the presence of defects in the rotor windings current path, the DC-resistance of the stator windings is determined by means of a DC-current, which is conducted through the rotor winding in series with a calibrated shunt. The test is normally performed between the slip rings. The DC-current must be large enough to enable accurate measurements, but shall not result in significant thermal effects during the measurement. The voltage across the shunt and the rotor winding is compared. During the measurements the temperature of the winding is recorded. For evaluation of the results a comparison is made with previous measuring results, such as obtained by the manufacturer in the factory.

For this purpose the results mostly are corrected to a temperature of 75C. If the results are deviating from the expected values the cause should be traced. Any bad connection or defect in the terminals or (partly) interruption in the windings or leads may cause large damage to the machine.
ImPedanCe OF THe ROTOR WIndInGs

VoLtage withstand tests on the RotoR windings


Verication of the condition of the electrical coil insulation of rotor windings may be done by Megger testing followed by application of a prescribed power frequency voltage for some time. The coil insulation to earth or to neighbouring coils is tested with short-circuited rotor windings. Generally the voltage will be less than the level of the original factory acceptance test.

In order to detect presence of defects in the rotor windings current path, the 50/60 Hz power frequency impedance of the stator windings is determined by means of an AC-current, which is conducted through the rotor winding. Then voltage across the slip rings is measured. The test is normally performed between the slip rings. The AC-current must be large enough to enable accurate measurements but shall not result in significant thermal effects during the measurement. Subsequently the 50/60 Hz power frequency impedance of the rotor winding was determined. The accuracy of the measurement depends on several factors. For instance the wave shape of the harmonic current may be crucial. For evaluation of the results, a comparison is made with previous measuring results, such as obtained by the manufacturer in the factory.

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RSO-measURemenT On THe ROTOR WIndInGs

In order to test the performance of the rotor windings RSO (Recurrent Search Oscillogram) measurements are conducted. For the test a transient signal with respect to the rotor shaft is injected in each of the slip rings. A voltage impulse generator is connected between one of the slip rings in turn and the rotor shaft. The impulse voltage and the resulting current are fed into a transient recorder. The admittance as a function of the frequency will be determined as the twenty-fold logarithmic ratio of current and voltage, for each frequency component resulting from the Fourier transform and is expressed in dB. From the resulting current the admittance can be derived. The admittance of the two branches of the rotor winding relative to the rotor shaft will be measured. The admittance characteristics should show no difference. The test is performed with the rotor in standstill mode, or if possible, in running mode, at various speed adjustments. Additional information about the condition of the rotor windings can be found by comparison of the transient behavior of symmetrical winding branches, each connected to a slip ring.
InsULaTIOn ResIsTanCe OF THe ROTOR WIndInGs and deTeRmInaTIOn OF THe POLaRIZaTIOn IndeX

Megger. During the measurement a DC-voltage of approximately 500 V is applied. The measurements are performed as a function of the time after application of the voltage. The measurements are performed on the rotor winding with the other machine winding earthed, together with the frame of the stator. It is important to register the temperature of the winding for the evaluation of the result. The leakage current that occurs when the winding insulation is subjected to a DC-voltage is a measure for the condition of its insulation. A distinction can be made here between the timedependent effects during the charging of the winding capacitance and the non-time-dependent effects which occur as a result of moisture and/or tracking inside or on the surface of the winding insulation. The leakage current is measured at a specified DCvoltage level by means of an insulation resistance meter (Megger). From the measured insulation resistance as a function of the time, the polarization index is determined. The ratio of the insulation resistance values measured 10 minutes and 1 minute after the application of the DC-voltage, is called the polarization index. The polarization index and the insulation time constant are measures for the evaluation of the insulation condition with respect to cleanliness and the presence of moisture. The temperature of the winding is of importance.

To determine the polarization index and insulation resistance of rotor windings a dedicated test can be performed. The insulation resistance of the rotor windings is measured by means of a digital

The admittance is presented in curves for the circuit inner slip ring to shaft (curves inner long and inner short) and for the circuit outer slip ring to shaft (curves outer long and outer short). The expression short and long relates to the length of the applied interconnecting cable wires between pulse generator and rotor. The length of the cable wires is of minor importance on the measurement. Furthermore, for frequencies up to 20 kHz, the admittance of both circuits is identical.

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ELECTRIC TESTING OF STATORS


Reliable operation of a generator is highly dependent on the electrical and mechanical integrity of stator winding. Operating temperature, operating voltage stress and thermal-cycle stress cause damage to the stator insulation.
Failure of a generator stator conductor due to electrical or mechanical problems will lead to long forced outage of the unit resulting into huge revenue loss. Therefore it is necessary for judgment of insulation deterioration to carry out a diagnostic test of the stator coil. To evaluate the residual life from experience and the accumulated data, DNV KEMA offers a full set of diagnostics to assess the generator stator condition, like: Insulation resistance Polarization index Capacitance and dielectric losses Partial discharge Voltage tests
MeasURemenT OF THe DC-ResIsTanCe OF THe sTaTOR WIndInGs

measurements but shall not result in significant thermal effects during the measurement. The voltage across the shunt and the stator winding is compared. During the measurements the temperature of the winding is recorded. For evaluation of the results a comparison is made with previous measuring results, such as obtained by the manufacturer in the factory. For this purpose the results are mostly corrected to a temperature of 75C. If the results are deviating from the expected values the cause should be traced. Any bad connection or defect in the terminals or (partly) interruption in the windings or leads may cause large damage to the machine.
InsULaTIOn ResIsTanCe and POLaRIZaTIOn IndeX OF sTaTOR WIndInGs

In order to detect presence of defects in the stator windings current path, the DC-resistance of the rotor windings is determined by means of a DC-current, which is conducted through the stator winding in series with a calibrated shunt. The test is normally performed between the slip rings. The DC-current must be large enough to enable accurate

To determine the polarization index and insulation resistance of stator windings a dedicated test is performed. The insulation resistance of the stator windings is measured by means of a digital Megger. During the measurement a DC-voltage is applied ranging from 500 5000 V. The measurements are performed as a function of the time after application of the voltage. The measurements are performed on the stator winding with the

Non-destructive testing & plant diagnostics ENERGY 17

other machine winding earthed, together with the frame of the rotor. It is important to register the temperature of the winding for the evaluation of the result. A distinction can be made here between the time-dependent effects during the charging of the winding capacitance and the non-time-dependent effects which occur as a result of moisture and/or tracking inside or on the surface of the winding insulation. From the measured insulation resistance as a function of the time, the polarization index is determined. The ratio of the insulation resistance values measured 10 minutes and 1 minute after the application of the DC-voltage, is called the polarization index. The polarization index and the insulation time constant are measures for the evaluation of the insulation condition with respect to cleanliness and the presence of moisture. The temperature of the winding is of importance. For modern epoxy-resin insulated windings the insulation resistance should be more than 1000 M at 20C and the polarization index PI should be in accordance with the IEEE 43 standard.
CaPaCITanCe and dIeLeCTRIC LOsses (Tan-)

depend on temperature and frequency. The capacitance of the winding at 0.2Un is of vital importance to find out whether major changes have occurred in the insulation. The capacitance of the windings depends on the relative dielectric constant of the insulation. The capacitance is subject of voids and gaps in the insulation. For the purpose of these measurements a Schering bridge is used with a loss-free standard capacitor. The measurements are performed as a function of the voltage between for example 0.2 and 1.0Un in steps of 0.1Un. The measurements can be performed part-wise, mostly per phase, on the individual parts of winding with the other parts connected to earth and to the stator frame. The dielectric loss angle of the insulation and the capacitance of the stator windings are determined. The measurement can be done very accurately and reliable.

In oRdeR to assess the condition of the geneRatoR statoR, DNV KEMA offeRs a fULL set of diagnostics sUch as
Insulation resistance Polarization index Capacitance and dielectric losses Partial discharge Voltage tests

Dielectric losses and capacitance of the winding will increase with the voltage because voids (gaps) inside the insulation will be short-circuited as a result of occurring partial discharges. The dielectric losses of the insulation represent the relation of the resistance to the capacitive impedance. The dielectric losses

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From the average value of the maximum rise of Tan- with voltage, compared with the values obtained during previous measurements, it can be determined whether the volume of air inside the insulation has changed. The relative capacitance change is a measure for the total air volume which is shortcircuited by internal partial discharges.
PaRTIaL dIsCHaRGes

known partial discharge intensity. During the partial discharge measurements the entire winding - from phase connection to star point - is energized at a certain voltage level with respect to earth. In practice, when the machine is under normal service conditions, the voltage is distributed equally along the winding from the star point of the machine to the phase connection. Different partial discharges: Slot discharges occur in a slot in the stator between the bar including its insulation and the stator. This can be the result of degradation or damage to the semi-conducting layer on the surface of the bar insulation.

Partial discharges may occur due to discontinuities in the insulation. Partial discharges give an indication of abnormalities. It is important to know how the test is performed. The partial discharge measurements are performed with a multi-channel, phase-related partial discharge detector. Prior to each test, a calibration is performed on each side of the generator winding by means of an impulse-generator giving a repeating pulse with

The partial discharges are recorded during a period of approximately one minute at voltage levels of 0.6Un and 1.0Un at a frequency of 50 Hz. Based on these measurements, graphs can be plotted in which the intensity of the partial discharge level is presented as a function of the phase angle at which the discharge occurred. Within these graphs, different intensities are presented in different colors. The graphs can contribute to the interpretation of the test result, since the shape of a partial discharge pattern depends on the location where the discharges occur. Some of the recorded patterns show an asymmetry between the discharges in the positive and negative half-cycle of the voltage sine wave. This is typical for discharges other than internal discharges, which show a more symmetrical pattern.

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End winding discharges can occur at the location where the bar extends out of the slot. To prevent partial discharges a corona protection layer is applied at this location. When this layer is damaged, partial discharges can occur here. Internal discharges occur in the insulation around the conductors, mostly caused by detachment of the different layers in the insulation (delamination). Gaps/voids, originated during the manufacturing process, can also be the cause for this type of partial discharges. Bar-to-bar discharges can occur at the end winding between two bars of different phases or between a bar at high-voltage and a neutral bar. In general, this type of discharge can occur between two separate bars next to each other when a too high voltage difference exists between them resulting in a too high electrical field.

tooth tips and slot walls, and possible surface damage, without the normal problems when testing with high excitation. This methodology is called the ELectromagnetic Core Imperfection Detector (ELCID) and is accepted worldwide for reliable and safe detection of stator core inter-laminar faults. ELCID operates at only 4% of the normal operating flux. This low flux is generated by a portable, quickly installed excitation kit. Any imperfection in the core inter-laminar insulation produces fault currents, which are detected by a Chattock coil and analyzed by the ELCID signal-processing unit. These Chattock coils are mounted on a Generator Inspection Vehicle (GIV), which is developed by DNV KEMA, in order to perform the ELCID test without necessity of removing the rotor. Measurement results are digitally stored for analysis and report generation to precisely locate the faults in the stator core. Future results can be compared to past results for trend analysis. This GIV is also used when testing stator wedges on integrity and eventual detachment (tap testing). The vehicle is then provided with equipment for mechanical excitation of the wedges and detection of the impulse response (WTA: Wedge Tightness Assessment). Cameras are mounted on the GIV in order to perform various visual inspections.

VOLTaGe WITHsTand TesTs On THe sTaTOR WIndInGs

As a further check on the insulation of the stator windings, and depending partly on the size of the generator (or motor), it may be desirable to perform a voltage test, as well as measuring the capacity, loss angle and partial discharges. The test method, appropriate voltage strength and test duration are preferably decided on the basis of consultation with the user and manufacturer.
ELCID TesT

Defects in inter-laminar insulations of stator cores in rotating electrical machines such as generators and electro motors cause fault currents to flow locally in the core, which may result in local overheating or hot spots in damaged areas. These hot spots should be detected and repaired during routine machine overhauls. The conventional testing method for measuring these core faults is known as the full ring flux testing method. This methodology requires the core to be excited to near its normal working flux level for a period of time. An alternative method to detect faults in core inter-lamination insulation by electromagnetic means was developed in 1978. Instead of the full flux working level, this newer method uses only a small fraction of excitation to generate fault currents within the core body which are sensed by a pick-up coil. This provides an accurate indication of damaged parts, including

Key benefits of the ELCID test


Tests are repeatable Immediate test results available for local analysis Determination of exact location of defects: on the (sub)surface or under conductors Tests with or without windings in place Allows partial retests of a core, results can be merged to obtain a complete view of the core condition Tests can be performed with the rotor in-situ

N.V. KEMA Utrechtseweg 310, 6812 AR Arnhem, The Netherlands I Tel: +31 26 356 9111 I Fax: +31 26 443 4025 emea@dnvkema.com I www.dnvkema.com ABOUT DNV KEMA EneRGY & SUsTaInaBILITY DNV KEMA Energy & Sustainability, with more than 2,300 experts in over 30 countries around the world, is committed to driving the global transition toward a safe, reliable, efcient, and clean energy future. With a heritage of nearly 150 years, we specialize in providing world-class, innovative solutions in the elds of business & technical consultancy, testing, inspections & certication, risk management, and verication. As an objective and impartial knowledge-based company, we advise and support organizations along the energy value chain: producers, suppliers & end-users of energy, equipment manufacturers, as well as government bodies, corporations and non-governmental organizations. DNV KEMA Energy & Sustainability is part of DNV, a global provider of services for managing risk with more than 10,000 employees in over 100 countries.

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