30 Years Experience with EL CID Stator Core Testing

John Sutton, Inventor of EL CID Mladen Sasic and David Bertenshaw, Iris Power LP Introduction The Electromagnetic Core Imperfection Detector (EL CID), a method of detecting faults in core interlamination insulation by electromagnetic means, was developed by the Central Electrical Research Laboratory (CERL) of the United Kingdom Central Electricity Generation Board (CEGB) and patent applied for in 1978 [1]. EL CID has been commercially available in a number of different products since the early 1980s. A short summary of the past 30 years of EL CID and present state of EL CID technology will be presented in this paper. Background The stator core of a typical large (e.g. 500MW) turbogenerator weighs 200 tonnes, is 6m long 2.6m in diameter and has a bore of 1.3m. It is built from a stack of some 200,000 individual steel sheets or laminations each 0.3 to 0.5mm thick and coated on each side with a layer of electrical insulation to prevent current flow between them. If this insulation is damaged on a group of laminations, an electrical circuit can be created and the machines rotating magnetic field will then induce a current around the circuit, which can create a hot spot within the stator core.

Figure 1. Currents induced in a laminated core due to inter-lamination damage at the base of a slot

Electrical faults in the stator cores of large generators can lead to spectacular and catastrophic failures. Frequently, the only repair option available after such events is complete stator core and stator winding replacement. The CEGB experienced a number of such generator stator core failures in early 1970s. During a three month period in 1969/1970 winter, stator core faults occurred in four 500 MW generators installed at one station [2]. In total, eleven stator core faults developed in 500 and 660 MW CEGB generators in early 70s. 1

At the time, the only method of testing inter-laminar insulation in stator cores was the High Flux Ring Test (or Loop Test). This requires the rotor to be removed and a massive excitation winding to be installed through the core to generate a circumferential, or ring magnetic flux around the core. To provide the required level of flux (typically 80% of rated flux), several loops of high voltage, high current carrying capacity cable need to be connected to a high power source (3-4 MVA for a 500MW generator). Ideally the core is energised for a few hours to produce measurable tooth tip temperature rises for deep-seated faults located near slot bases. Hot spots are then detected using thermal sensing equipment. The principal disadvantages of the Loop Test are the installation of the winding, the high power requirements, high voltage safety concerns, the difficulty of detecting deep-seated faults and risk of further core damage due to the normal cooling systems being absent. A research team was set up at the main CEGB laboratory to investigate the spate of core failures. A full understanding of the failure mechanisms was established and EL CID was developed as an alternative to the Loop Test, overcoming most of its disadvantages. Principle of the EL CID Test EL CID also uses a temporary ring flux winding but it is much lighter and requires only a 3kVA supply for a typical 500MW turbo-generator! The flux produced is only 4% of the rated value so only small currents flow through any damaged areas (typically between the fault and rear building keybars as shown in Figure 1). The heating is insignificant but EL CID measures the current through the faults electromagnetically, even if the damage is deep down in the slots between the teeth. A special pickup coil, known as a Chattock Potentiometer [3], is used to measure the magnetic fields produced in the air by current flowing along the core surface. The Chattock magnetic potentiometer consists of a long thin solenoid uniformly wound on flexible former. The voltage induced in the coil is proportional to the line integral of the magnetic field along its length, i.e. to the magnetic potential difference (m.p.d.) between its ends. According to Amperes law this integral along any closed path around a conductor is equal to the current, I, in the conductor.

Figure 2. According to Amperes law the line integral of the magnetic field, H, around a current, I, is equal to the current. The component in the air is almost equal to the fault current.

When the current is flowing along an iron surface, as in Figure 2, the magnetic field in the iron is much less than it is in the air because of the high permeability of the iron (typically 2000, vs. 1 for air). Hence the line integral of the magnetic field in the air is almost equal to the current, and the Chattock output voltage is a good measure of the current when its two ends are placed on the iron to bridge the current.

Figure 3. Chattock potentiometer positioned across a pair of teeth encompassing a fault. For the EL CID test the Chattock potentiometer spans across the farthest corners of adjacent teeth as shown in Figure 3. The magnetic potential measured by the Chattock potentiometer is usually dominated by the magnetic field from the excitation current rather than the smaller field caused by any current flowing through a fault, such as shown in Figure 3 on the tooth tip. The induced voltage driving the fault current is proportional to the inverse of the rate of change of excitation flux, and is thus in phase quadrature to the excitation flux, as shown in the basic vector diagram, Figure 4 (though the overall process is more complex [4]).
Excitation flux

If

Ifq Fault current/flux in quadrature

Vf Voltage induced in fault

Figure 4. Vector diagram of excitation flux and fault voltages and currents. Since the fault current circuit has a significant resistance, the fault current is substantially in-phase with the fault voltage and therefore in phase quadrature with the excitation flux. EL CID exploits this phase relationship and virtually eliminates the signal from the excitation current by using a phase sensitive detector to measure this quadrature component of the fault current (also the heat producing component). This is referred to as the QUAD (or Q) component, the part in phase with the cxcitation

current is called the PHASE (or P). The reference signal for the phase sensitive detector is obtained from a transducer measuring the phase of the excitation current. To carry out a full EL CID test the Chattock is adjusted to the slot as shown in Fig. 3 and it is scanned along each and every tooth pair and the responses are recorded. These traces are examined and faults are apparent when the quadrature component exceeds a certain threshold (usually 100mA). The Original CEGB Equipment

Figure 5. The original CEGB EL CID equipment Figure 6. An early CEGB EL CID test Figure 5 shows the original EL CID equipment that was designed and built by the CEGBs Central Electricity Research Laboratory (CERL). Five such sets were provided for use within the CEGB and Figure 6 shows an early test being carried out on a large generator. Following positive test results it was decided to licence the technology for commercial exploitation and an exclusive agreement was set up with ADWEL Industries Ltd. in 1982, with complete ownership transferred in 1996. Early Commercial Products

Figure 7. The Core Check.

One of the first commercial products was the Core Check, Figure 7, a hand-held instrument with rigid fixed-length Chattock sensors, 40 and 60 mm long. The instrument had two measurement ranges 500 mA and 1 A. There was no dedicated reference signal input; the reference signal was provided 4

from the power supply connected to the instrument. Fault amplitude was displayed using a LED display.

Figure 8. The Motor Core Tester. The Motor Core Tester, Figure 8, had a dedicated reference input and the output signal was displayed on an analogue meter. Both the Core Check and The Motor Core Tester were designed for testing smaller cores and neither had means for recording test results. An updated version of the Motor Core Tester, the MCT2, continues in production. The first commercial version of EL CID, based on the CEGB design, was released in 1982. The complete kit, Figure 9, consisted of a Signal Processing Unit (SPU), an X-Axis Transducer, excitation cables, different sizes of Chattock sensors and a plotter. This only later became known as the Analogue EL CID after the Digital model was introduced.

Figure 9. Analogue EL CID kit, Model 201.

Figure 10. Schematic showing Analogue EL CID set-up for large turbo-generators. As in the CEGB equipment, the Chattock potentiometer was mounted on adjustable low friction runners and housed in the sensing head. An X-Axis transducer, using a pull cord, enabled the EL CID traces to be recorded on a plotter as the sensing head was scanned along the stator slots. A smaller Chattock potentiometer with adjustable arms was used to exactly locate and measure faults identified during the main scan. The measuring range of Analogue EL CID was up to 50 A and this feature enabled EL CID to be used near the splits in the cores that often are present in large hydro-generators. Even thought the system was originally conceived for turbo-generators, hydro-generators proved to also be a popular application for EL CID because of the particular difficulty in exciting such large machines for the High Flux Test. While an add-on Computer Interface was developed for the Analogue EL CID, it had become clear that a new direction was needed to provide accurate and comprehensive data records of test results. Consequently the Digital EL CID Model 601 was introduced in 1995 shown in Figure 9.

Digital EL CID Model 601

Figure 9. Digital EL CID Model 601

The following list identifies a few of the key improvements in Model 601 and the associated benefits: Signal Calibration: Whereas the Analogue unit simply provided a facility to perform a system test, the Digital EL CID is fully calibrated. A calibration unit, provided as standard with the kit, allows the user to calibrate the sensor (Chattock potentiometer) and the EL CID prior to each test. This ensures that each test, regardless of sensor or operator, is carried out at the same sensitivity a necessity for trending suspect areas. The calibration would also identify a faulty Chattock prior to a test. Manual Trolley: The manual trolley replaces the original sensing head that housed the Chattock potentiometer. The trolley has wheels and is magnetically attached to the core and completely adjustable to suit variations in slot width and core radius. The trolley is much easier to use and reduces operator fatigue (especially when working overhead). Distance Measurements: Distance along the stator core is no longer measured by the pull cord of the X-Axis Transducer. Instead, the manual trolley also has a wheel with a distance encoder that tracks the distance along each slot as it is scanned. The encoder, which can be calibrated prior to each test for accuracy, also allows an operator to re-trace any suspect areas without having to repeat a slot scan. There is no limit to the length of a scan as there was with the X-axis transducer. Total Signal Capture: With the Analogue system the operator was able to collect QUAD and PHASE data only by repeating the test in the two modes. The Digital EL CID equipment simultaneously collects both QUAD and PHASE information for improved signal analysis. RF/EMC Noise Immunity: As with any analogue system, the Analogue EL CID was susceptible to RF noise while working in the field. This has been greatly reduced with the analogue to digital conversion circuitry of the Digital EL CID.

Computer Operated: Initially, two separate DOS applications were used for data acquisition, (ACQUIRE) and data analysis (ELPLOT). Later, Windows-based software has improved operator interface making easier to set up. Additional benefits included the ability to view and analyze data in several ways as well as to generate detailed end-user reports for future reference. Traces for slots where the signal exceeds 100mA (or any other user-set threshold) are drawn in a different colour for easy identification. There is also the facility to record data for the step irons of the stator ends. Computer Records: The data is saved in the computer for both PHASE and QUAD values (and EL CID Calibration data) for each 2mm of each core slot. This data can be analyzed later offsite, sent by email to others for their opinions, and saved for comparison with later results. The data can also be exported to spreadsheets/databases for other analysis.

The complete system connections are shown in Figure 10. A later development for the Digital EL CID kit was a complete and extendable excitation system for turbo- and hydro-generators, which incorporated a trace winding to measure the excitation flux (voltage) level. Further improvements in hardware and software also enabled one-man operation, by allowing the trolley operator in the stator core to remotely control the PC.

Figure 10. Digital EL CID Model 601 connections

As well as product development, many important stator core test studies and publications have been completed. Amongst these a book was written on the use of the EL CID system for the testing of hydro-generators, with particular reference to the techniques necessary to accommodate the various distortions caused by machine construction [5]. The importance of detecting and avoiding or allowing for circulating currents in machine windings was also finally understood with recommendations published for hydro and turbo generators [6, 7], and some important theoretical modeling was completed to assist in fault detection and interpretation [8, 9]

Digital EL CID Model 601 continued in production until late 2007, when it was replaced with the new model, EL CID Evolution. EL CID Evolution After 12 years of successful service, it become apparent that a number of improvements could be made to the Digital EL CID system to make testing easier and faster, and also due to the relentless acceleration of electronic technology, a redesign was anyway required to continue production! Consequently this next generation instrument was launched in 2007, shown in Figure 13, still maintaining the proven success of the basic principles.

Figure 13. EL CID Evolution SPU

High-speed digital signal processing computes the PHASE and QUAD values from an agile frequency reference, with clear user interface and data interfacing managed by a Linux-based control processor. Based on customer feedback and in-house experience, EL CID Evolution has a number of significant advantages: A Large LCD display with on-screen guidance helps the user to set up the test. A separate Setup page shows all the calibration values for user record and adjustment. There are two Chattock inputs that connect to the two Chattocks on the Remote Inspection Vehicle (RIV, see below). This allows the full length of a slot to be measured in a single return scan. The resolution has been increased from 12 to 16 bit, giving improved accuracy and 200% overrange margins. This enables a larger range of cores to be tested without having to switch ranges. A USB interface for simple, auto-detect connection to the PC. Automatic and complete 50-60Hz Chattock compensation. Faster operation up to full nominal speed (up to 120mm/sec @ 60Hz). Separate X-axis calibrations for the Trolley and RIV. On-screen QUAD Bargraphs and battery operation allows use in the stator core for localising faults (as in figure 12). Robust locking insulated connectors that eliminate the possibility of electrical damage to the core. New custom-designed SPU case provides complete insulation and rugged construction for service.

Figure 12. EL CID Evolution during a test.

To further enhance the new instrument, substantial additions were also made to the ELAN PC software. These include: Computation models to assist excitation calculation, using either winding details or core geometry. The two Chattock signal inputs are automatically switched between forwards and backwards travel when using the RIV. Data can now be merged from separate part tests to form a complete test file, including any stepiron tests done with the time-base mode. Minor errors in X-Axis calibration can be accommodated by offsetting backward traces to align with forward ones. The Slot List, Peaks and Notes can all be copied to the PC Clipboard to assist electronic report generation. A particularly interesting development is the ability to present a false-colour, visualisation map of the data, in a manner as if a thermal image had been unrolled, as shown in figure 13 for a fault in slot 22.

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Figure 13. Core Visualisation of a Turbo-generator Fault These improved software features remain compatible with all earlier versions, so todays software can be used to operate the very first Digital EL CID. Robotics in EL CID Testing An automatic scanning system was developed by the CEGB in 1982 in which the Chattock potentiometer was moved along a beam clamped to the surface of the bore. This reduced test times and gave more reproducible test results. Automatic testing was later improved by a vehicle developed by National Power (previously part of the CEGB) which was magnetically attached to the stator surface and was steered itself along the stator teeth. This vehicle was further developed by ADWEL in cooperation with the French Utility EDF and resulted in the Robotic Inspection Vehicle RIV-702, which became commercially available in 1997.

Figure 14 Robotic Inspection Vehicle Model 702

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The Robotic Inspection Vehicle (RIV) and accessories, Figure 14, allows remote and robotic testing to be achieved. The vehicle is attached magnetically to the stator teeth, and guides itself along each slot using magnetic sensors, thus avoiding the need for operator steering to achieve correct alignment. The RIV is of particular value when there is only limited access in a small stator, or when a large amount of testing requires automation to reduce the labour involved (e.g. large hydrogenerators). The greatest gain however comes in allowing tests to be performed with the rotor still in place, where the RIV can be run inside the rotor-stator air-gap. Chattocks can be mounted on both ends of the RIV to allow complete coverage of the whole core without the RIV having to exit either end. Figures 15a and 15b show the RIV being launched into air-gaps in typical situations, which are always very tight!

Figure 15a. RIV entering air-gap (500MW)

Figure 15b. RIV entering air-gap (150MW)

This test method is usually restricted to larger turbo-generators from about 200MW upwards, depending on access past the rotor end rings. In hydro-generators the pole air-gap is usually too small, but the gap between the poles can be exploited, possibly with a pole removed, then the rotor turned to allow testing of the whole core. In rotor-in-place testing the excitation cables cannot be taken down the centre of the bore, but must instead be threaded through the air-gap between the stator and rotor. It may be expected that this will lead to rather asymmetric excitation of the core, however F.E.A. analysis of a typical 48 slot turbogenerator has shown that the effect of the iron in the rotor is to linearise the magnetic field at its surface, so the flux remains uniform in the main core. The only precaution that needs to be taken is the usual one of making sure that the Chattock does not approach too close to the excitation cable to avoid interference from the winding leakage field. The ability to introduce the RIV into the air-gap with the rotor still in place also allows measurement of wedge tightness and visual inspection. The RIV has been further adapted to carry a low-profile WDT501 Wedge Tightness Probe, allowing a survey of the wedging system without rotor removal.

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Figure 16a RIV with video-camera installed

Figure 16b RIV camera output (side view)

The RIV can be fitted with a video camera and integrated illumination system without increasing the overall height, as shown in Figure 16a. A rotating mirror and alternate mounting positions permits inspection in any direction and remote focusing allows close-up or distant views, as in Figure 16b. Conclusion The EL CID system has seen now three decades of successful use. The basic technique has remained unchanged but three generations of product development have resulted in considerable improvements in the hardware and software. A number of supporting developments have been introduced to assist its implementation as user confidence in the process has grown. EL CID can fairly be said to be in use in every continent on the globe now, and has achieved recognition by CIGRE, the leading worldwide organisation on Electric Power Systems: There seems to be general consensus that if an EL CID test is performed and no damage is found, then the core is defect free. EL CID has gained good credibility in its ability to determine and locate the presence of faults and to verify repairs when faults are found.[10] References 1. Method and apparatus for testing laminated magnetic cores. John Sutton., UK Patent No. GB2044936, granted 6th January 1983 2. Can you believe your GCM, D. J. Wallis, Innogy and Steve Kilmartin, E-One, Eighth EPRI Generator Workshop, Nashville 2003. 3. On a magnetic potentiometer. Chattock A. P., Phil. Mag. 24, pp 94, 1887. 4. Analysis of stator core faults - a fresh look at the EL CID vector diagram, David Bertenshaw, Hydro 2006, Porto Carras, Greece. September 2006. 5. EL CID Application and Analysis, Edition 3, G. K. Ridley, Book published by ADWEL International Ltd and Iris Power LP, 2007, ISBN 0-9539465-0-9. 6. Effects of Stator Windings on EL CID Measurements, John Sutton, Brian Chapman, David Bertenshaw, EPRI Winter 2004 Technical Workshop and Generator Core Inspection (EL CID) User Group Meeting, Albuquerque, USA, 20th January 2004. 7. Application of the EL CID Test with Circulating Currents in Stator Windings, David Bertenshaw, John Sutton, Inductica, Berlin, Germany, June 2004.

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8. Theory of Electromagnetic Testing of Laminated Stator Cores. Sutton J., British Journal of Nondestructive Testing April 1994. 9. Computational Modelling of Stator Core Faults in Large Hydrogenerators and Turbogenerators, David Bertenshaw, Alexander Smith, Trina Chan, Choon Ho, Hydro 2004, Porto, Portugal, October 2004. 10. EL CID (Electromagnetic - Core Imperfection Detector) Testing of Large Steam-Turbine-Driven Generators, CIGR Report 257, 2004

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