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EL CID

The Modern Way to Test Stator Core Insulation

Why Core Test?

Predictive Maintenance

Service/Repair

Manufacturing/QA

Requirement for Core Testing


Predictive Maintenance:

Identify Repairable Damage Reduce Unscheduled Outages Schedule Necessary Repairs

Improve Efficiency through Reduced Thermal Stresses


Prolong Machine Life

Requirement for Core Testing


Service/Repair:

Determine Fault Location Assess Severity of Fault

Monitor and Verify Repairs

Requirement for Core Testing


Manufacturing/Quality Control:

Quality Assurance/Quality Control Baseline Results for Machine Owner Acceptance Testing

Common Causes of Damage

Relaxation of Core Clamping Failure of Inter-laminar Insulation

Thermal Creeping
Loose Debris Rotor Rub Loose Coils, Wedges

Fault Current

Fault Current

Sample Core Damage

Accepted Test Methods


1) High Power Ring Flux Test - the LOOP test

Large Power Supply Required Safety Concerns with High Current

Expensive Thermal Sensing Equipment

2) Electromagnetic Core Imperfection Detector - ELCID

Low Power Requirements

No Safety Concerns due to High Current

PROBLEMS WITH HIGH POWERED RING FLUX TEST

AVAILABILITY OF POWER RUNNING HIGH CURRENT/HIGH VOLTAGE CABLES AND MECHANICAL STRESSES

TIME REQUIRED FOR TEST MANPOWER REQUIRED FOR TEST SAFETY PRECAUTIONS AND PROCEDURES NO ACCESS TO STATOR BORE WHILE THIS TEST IN PROGRESS COOLING OR HEATING TIME BETWEEN TEST/REPAIR/ TEST ETC. POSSIBILITY OF INCREASED DAMAGE DUE TO TESTS - NO COOLING ETC. -

PHYSICALLY SMALL BUT SERIOUS FAULTS NOT ALWAYS DETECTABLE IF DEEP SEATED OR BENEATH WINDINGS

THE SOLUTION - ELCID


INITIALLY DEVISED BY CEGB - LOW EXCITATION POWER REQUIREMENTS FAST - EASILY SET UP LOW MAN POWER REQUIREMENTS

NO SAFETY HAZARDS OR COMPLICATIONS


INSTANT TEST RESULTS STATOR CAN BE REPAIRED SIMULTANEOUSLY WITH FURTHER TESTING - NO NEED TO COOL DOWN OR DISMANTLE TEST GEAR POWER LEVEL TOO LOW TO CASE FURTHER DAMAGE FAULTS NOT OBSCURED BY WINDINGS SPEED ALLOWS FAST TESTS TO BE CARRIED OUT BEFORE AND AFTER OTHER MAINTENANCE WORK (E.G. WEDGING) AUTOMATIC PERMANENT RECORDS FOR FAULT H ISTORY MONITORING OR QA PROCEDURES EQUIPMENT VERY PORTABLE

Typical Hydrogenerator Excitation System

Typical Turbo generator Excitation System

System Configuration

Positioning the Chattock

Interpretation of Data

Required Excitation Levels

Loop Test

ELCID

100% +
(of rated flux density)

4%

System Configuration

Measuring Fault Current with a Chattock Potentiometer

Digital ELCID - Model 601

Method of Scanning

Method of Scanning

Business Justifications

Improved Machine Efficiency Increased Reliability Reduced Outages Reduced Power Consumption during Test

Alternator with Rotating Field

Functional Layout
Reference Coil Chattock Coil Distance Transducer

Signal Conditioning A/D Converter Digital Processor RS-232 Interface

Distance Encoder

D/A Converter

Portable Computer

X-Y Chart Recorder

Advantages
Low Excitation Power - 4% Fast - Easy to Setup

Low Manpower Requirements Significant Reduction in Safety Hazards Instant Interpretation of Test Results Minimal Risk of Further Damage

Ability to Re-Test During Maintenance Cycle Permanent Data Storage Portability

Suggested Usage
Predictive Maintenance:

Global Scan at available planned intervals

Service/Repair:

Beginning of the Maintenance Cycle During Repair Procedures After Completion of Work Throughout Stacking Process QA for Final Acceptance Acceptance Baseline Test for End-User

Manufacturing/Quality Control:

Excitation & Induced Voltages Across Laminations

Flux produced by Excitation Voltage induced across one pair of laminations Voltage induced across damaged laminations Voltage induced along complete core length

Excitation, Fault Volts and Fault Current

Flux produced by Excitation Voltage induced across damaged laminations Fault Current Phase angle that Fault Current lags Fault Voltage

Excitation, Fault Volts, Fault Current and Quad Fault Current

Flux produced by Excitation Voltage induced across damaged laminations Fault Current Quadrature component of Fault Current Watts dissipated due to fault

Excitation, Fault Volts and Fault Currents 1 & 2

Flux produced by Excitation Voltage induced across damaged laminations Phase Angle for If1 Fault Current 1

Fault Current 2

Phase Angle for If2

Quadrature Fault Current 1 Quadrature Fault Current 2

Sample Fault Indication (Turbo)