Michael Krger OMICRON

ROTATING ELECTRICAL MACHINES

Introduction

Rotating Electrical Machines
Design, Faults and Diagnostic Measurement Methods
Page 2
Introduction

Stator Winding Design

Faults on Generators

Insulation Resistance and the Polarisation Index (PI)

Dielectric Response

Capacitance and Dielectric Dissipation (Power) Factor

Partial Discharge (PD) Measurement

Case Study - Measurements on a Hydro Generator

Hydro Generator 11MVA
Page 3

Hydro Generator
Page 4

Hydro Generator 50MVA
Page 5

1000 MVA Generator (Steam Power Plant)
Page 6

90 MVA Generator (Steel Factory)
Page 7
14 MW Motors in a Steel Factory
Page 8

Stator of a Hydro Generator 50MVA
Page 9

Rotor Stator of a
Hydro Generator
Page 10

Rotor of a Hydro Generator
Page 11
Rotor of a Synchonous Motor
Page 12
Rotating Electrical Machines
Design, Faults and Diagnostic Measurement Methods
Page 13
Introduction

Stator Winding Design

Faults on Generators

Insulation Resistance and the Polarisation Index (PI)

Dielectric Response

Capacitance and Dielectric Dissipation (Power) Factor

Partial Discharge (PD) Measurement

Case Study - Measurements on a Hydro Generator

Design of a Machine Stator
Page 14
Stator Slot with Winding
Page 15

Conductor Design
Page 16

Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS J uly/August 2008
Stator Winding Insulation
Page 18
A. coating
B. wedge/spacer
C. main insulation (mica tape)
D. end corona protection
E. outer corona protection (OCP)
F. inner corona protection (ICP)
G. partial conductor insulation
H. slot closure
I. stator core
outer corona protection,
prevents slot discharges
between the exterior surface of
the insulation and the slot wall.
Graphite paper or graphite
coating
end corona protection
prevents surface discharges at the
exit point of the conductor from the
laminated stator core.
Made of materials with non-linear
conductivity (e.g. silicon carbide)
Stator Winding Insulation
Page 23
Rotating Electrical Machines
Design, Faults and Diagnostic Measurement Methods
Page 24
Introduction

Stator Winding Design

Faults on Generators

Insulation Resistance and the Polarisation Index (PI)

Dielectric Response

Capacitance and Dielectric Dissipation (Power) Factor

Partial Discharge (PD) Measurement

Case Study - Measurements on a Hydro Generator

Damage to Hydro Generators
Page 25

Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS J uly/August 2008
Sources of Insulation Damages
Page 26

Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS J uly/August 2008
Why do Rotating Machines Fail?
other; 3%
rotor winding;
10%
bearings and
vibrations; 50%
stator winding;
37%
Page 27
[IEEE85] Motor Reliability Working Group, Report of large motor reliability, survey of industrial
and commercial installations-Part I, IEEE Trans. Ind. Applicat., vol. 21, J uly- August, 1985
Why do Rotating Machines Fail?
Stator winding
stator core; 3%
partial conductor
insulation; 11%
mechanical
elements; 22%
main insulation;
64%
Page 28
[IEEE85] Motor Reliability Working Group, Report of large motor reliability, survey of industrial
and commercial installations-Part I, IEEE Trans. Ind. Applicat., vol. 21, J uly- August, 1985
Why do Rotating Machines Fail?
Page 29
Cigre Brochure 392
SURVEY OF HYDROGENERATOR
FAILURES
Working Group
A1.10
Page 30
Electrical Failures
Page 31
Delamination
Mechanical Abrasion
Insufficient contacting between corona
and end winding protection surface
Insufficient spacing, contamination
Electrical Failures
Perfect Mica Insulation
Page 33

Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS J uly/August 2008
Mica Insulation with Voids
Page 34

Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS J uly/August 2008
Electrical Treeing
Page: 35

Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS J uly/August 2008
Winding Insulation with Cracks
Page 36

Copper
Cracks
Main Insulation
Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS J uly/August 2008
Abrasion of the Slot Corona Protection
due to Vibration
Page 37

Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS J uly/August 2008
New Hydro Generator Bar with
Delamination in the Mica Insulation
Page 38

Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS J uly/August 2008
Hydro Generator Bar after 37 Years of
Service
Page: 39

Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS J uly/August 2008
Hydro Generator Bar after 40 Years of
Service
Page 40

Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS J uly/August 2008
Fault in the End Winding
Page 41
Faults in the End Winding
Page: 42
Source: VATech Hydro Austria
PD Fault in the End Winding
Page 43
Source: VATech Hydro Austria
Discoloration due to Leakage of Cooling
Water
Page 44

Source: Brtsch et al. "Insulation Failure Mechanisms of Power Generators", DEIS J uly/August 2008
Rotating Electrical Machines
Design, Faults and Diagnostic Measurement Methods
Page 45
Introduction

Stator Winding Design

Faults on Generators

Insulation Resistance and the Polarisation Index (PI)

Dielectric Response

Capacitance and Dielectric Dissipation (Power) Factor

Partial Discharge (PD) Measurement

Case Study - Measurements on a Hydro Generator

Insulation Resistance
Page 46
VE: Empfehlungen fr die Zustandserfassung der Aktivteile rotierender elektrischer Maschinen
dry
humid
Insulation Resistance Measurement
Page 47
Measurement Time Current
U-VWE 60 s 25.9809 nA
Measurement Time Current
U-VWE 600s 3.7637 nA
PI = 25.98 / 3.76 = 6.9

Time Constant
Page 48
dry
humid
Rotating Electrical Machines
Design, Faults and Diagnostic Measurement Methods
Page 49
Introduction

Design

Faults on Generators

Insulation Resistance and the Polarisation Index (PI)

Dielectric Response

Capacitance and Dielectric Dissipation (Power) Factor

Partial Discharge (PD) Measurement

Case Study - Measurements on a Hydro Generator

Dielectric Response
Combination of PDC and FDS
Page: 50
C
u
r
r
e
n
t

[
n
A
]

Zeit [s]
Trans-
formation
Frequency [Hz]
V
e
r
l
u
s
t
f
a
k
t
o
r



0,001
0,001
1
1000
1000 1
100
1
Frequenz [Hz]
T
a
n

D
e
l
t
a

1000
1
0,001
0,1
1. f > 0,1 Hz
Frequency Domain
2. f < 0,1 Hz
Time Domain
3. Transformation of the Time
Domain Data into the
Frequency Domain

Polarisations- und
Depolarisationsstrom
PDC
Frequency Domain
Spectroscopy
FDS
FDS Result
Page 51
PDC Result
Page 52
Rotating Electrical Machines
Design, Faults and Diagnostic Measurement Methods
Page 53
Introduction

Design

Faults on Generators

Insulation Resistance and the Polarisation Index (PI)

Dielectric Response

Capacitance and Dielectric Dissipation (Power) Factor

Partial Discharge (PD) Measurement

Case Study - Measurements on a Hydro Generator

Measurement of Dielectric Losses
Page 54
Dielectric losses in insulating systems (tan )
conducting losses (tan
C
)
polarization losses (tan
P
)
partial discharge losses (tan
PD
)
tan = tan
C
+ tan
P
+ tan
PD
Dielectric losses: tan = f (U)
Tip-Up Test according to IEEE 286 Tan-Delta Test according to IEC 60894
Test Equipment
Page 55

C-Range with 2 CR500
Page 56

LC
f
LC
C
L

2
1 1 1
= = =
L = 20H
Test Current with different Inductors
Page 57
0 H 80 H 40 H 26.6 H = 80 II 40
cap
ind
Test Setup C-Tan-Delta Measurement
Page 58
Rotating Electrical Machines
Design, Faults and Diagnostic Measurement Methods
Page 59
Introduction

Stator Winding Design

Faults on Generators

Insulation Resistance and the Polarisation Index (PI)

Dielectric Response

Capacitance and Dielectric Dissipation (Power) Factor

Partial Discharge (PD) Measurement

Case Study - Measurements on a Hydro Generator

PD Limits
Page 60
Offline Test
IEC 60037-27 U (V,W+Stator)
Page 61
IEC 60034-27
IEEE Std 1434-2000
Page 62
Cigre Brochure 258
Page 63
IEC 60034-27
Page 64
Rotating Electrical Machines
Design, Faults and Diagnostic Measurement Methods
Page 65
Introduction

Stator Winding Design

Faults on Generators

Insulation Resistance and the Polarisation Index (PI)

Dielectric Response

Capacitance and Dielectric Dissipation (Power) Factor

Partial Discharge (PD) Measurement

Case Study - Measurements on a Hydro Generator

Measurement on a 20MVA Generator
Page 66

C-Tan-Delta-Measurement
Page 67

C-Tan-Delta-Measurement
1,20
1,30
1,40
1,50
1,60
1,70
1,80
1,90
0,0V 1000,0V 2000,0V 3000,0V 4000,0V 5000,0V 6000,0V 7000,0V
%
Tan Del ta [%]
R
S
T
Page 68

C-Tan-Delta-Measurement
-0,20
-0,10
0,00
0,10
0,20
0,0V 1000,0V 2000,0V 3000,0V 4000,0V 5000,0V 6000,0V 7000,0V
%
del ta Tan Del ta
R
S
T
Page 69

C-Tan-Delta-Measurement
Page 70
Tan Delta (f) at 2kV
1.00
1.10
1.20
1.30
1.40
1.50
1.60
0.0 Hz 100.0 Hz 200.0 Hz 300.0 Hz 400.0 Hz
%
R
S
T
FDS / PDC Measurement
Page 71

FDS Measurement
Page 72

PDC Measurement
Page 73

Measurement Time Current
U-VWE 60 s 25.9809 nA
Measurement Time Current
U-VWE 600s 3.7637 nA
PI = 25.98 / 3.76 = 6.9

Synchronous 4-Channel Partial
PD Measurement
Page 74

Channel 1 = U1
Page 75

Channel 2 = U2
Page 76

Channels 3 and 4 = V1 and W1
Page 77

PD Calibration Matrix
Page 78


Cal Input 2nC 1 2 3 4
1 1.00 0.28 0.30 0.27
2 0.37 1.00 0.30 0.28
3 0.27 0.09 1.00 0.28
4 0.27 0.07 0.30 1.00
Channel
Synchronous 4-Channel PD Measurement
Page 79

3PARD
Page 80

3PARD = 3 Phase Amplidude Related Diagram
or in this case:
3 Channel Amplitude Related Diagram
Synchronous 3-Channel PD Measurement
with 3PARD Filtering Cluster A
Page 81

A
Synchronous 3-Channel PD Measurement
with 3PARD Filtering Cluster B
Page 82

B
michael.krueger@omicron.at
Questions and Remarks?