Back To Basics Generator

Testing and Inspection

ARIPPA Technical Symposium
17Aug16

Jamie Clark

AGTServices

A Few Thoughts
There is no replacing an experienced Generator Specialist
or expert for inspecting and testing generators!!

The DIRT tells a story. Dont clean it up before the

Specialist has inspected your generator!
There is no easy way, so dont take shortcuts!!
Speed does NOT equal a quality inspection (and will NOT
save you $$ in the long run)
Extending inspection intervals is proving detrimental to
generator reliability (new units are built with less margin,
less mass/MW, and lower cost materials)

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Session Objective
Identify Standard Tests and Inspections
Electrical

Mechanical
Visual
Examples Of:

bad test results

recommendation/corrective actions
good test results

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Purpose of Testing and Inspection

Identify & correct detrimental situations before
serious/expensive damage occurs
Provide confidence that the generator components will not
fail in-service prior to the next outage

Plan for future modifications, upgrades or repairs

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Stator Visual Inspection Summary

Complete all visual inspections prior to cleaning or testing
Note all areas of concern and advise owner / repair prior to testing
Perform cleaning prior to electrical testing
Cleanliness is important to achieving accurate test results
Perform suitability for service tests per Industry and / or OEM standards
& practices

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What to Inspect?

Stator winding

End winding support system

Wedge system
Gas gap baffle studs
Rubber baffles
Bushing box (H2 cooled)

Stator core

Tightness
Iron migration
Damaged / overheated
laminations
Vent duct blockage

Generator Field/Rotor

Overall cleanliness
Arcing between wedges/RRs
Hot spots on tooth tip at wedge joints
RR condition
Borescopic look under RRs
Collector ring condition
Fan damage
Copper dusting

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Heavy contamination

Greasing on Connection Ring

Blocking

Bar Bar Blocks & Ties Greasing

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Connection Ring Tie Wearing Into

Insulation

Slot PD Products

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Wedge System Condition

A visual wedge survey should be
performed
A wedge map should be made to
record the number of loose
wedges and the location
Manual vs Automated Tapper??

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Spark Erosion Damage

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Gas Baffle Condition

Missing Section of Gas Gap

Inlet Baffle

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Core Maintenance Issues

Core Tightness

Oxidation on back of core

Iron Oxide on wedges

Knife test

Building Bolt/Thru Bolt Torque Checks

Interlaminar Insulation Degradation

Mechanical Damage
Lamination Migration

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Core Tightness

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Torqueing
Thru Bolts

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Burning Due to
Loose Core
Loose Thru Bolts

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Bent
Laminations

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Burned Core Iron

Overheated Iron
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MeltedBent
Laminations
core iron
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Winding Resistance
Measure with Kelvin Bridge/DLRO
Determine if phase resistances:
Are balanced
Reflect design / factory
readings
Are consistent over time

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Winding Resistance as found

C
(LEFT)

B
(CENTER)

A
(RIGHT)

Resistance Taken @ 19OC

0.001067

0.000973

0.000981

Resistance Corrected to 25OC

0.001088

0.000992

0.001000

Resistance Corrected to 75OC

0.001298

0.001183

0.001193

Resistance Corrected to 100OC

0.001402

0.001279

0.001289

Phases should be balanced within 1% these are not

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Winding Resistance
Problem if:
Not balanced
Deteriorated bolted connection
Deteriorated braze or solder joint
Cracked/broken strands
Significantly different from factory /
historical tests
Poor test
Global deterioration

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Winding Resistance
Recommendations:
Search & Dissect

Strip & inspect bolted connection(s)

Bump Test / DLRO identify potential joints
Sample strip & inspect braze/solder joints
Sample strip to expose strands

Current Thru Winding & Thermo-Vision

Not an industry standard test
From experience
1000 amps/in2 of conductor cross section
Investigate > 5o C differential

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Soldered Joint Bad

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Winding Resistance as left

C
(LEFT)

B
(CENTER)

A
(RIGHT)

Resistance Taken @ 25.25OC

0.001016

0.001010

0.001012

Resistance Corrected to 25OC

0.001015

0.001008

0.001011

Resistance Corrected to 75OC

0.001200

0.001203

0.001206

Resistance Corrected to 100OC

0.001308

0.001301

0.001303

As-left, after performing series loop

solder repairs

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Insulation Resistance & Polarization Index

Generally referred to as Megger test
Per IEEE 43 & IEEE 95
For stator windings, typically performed at
either 2500 VDC or 5000 VDC (megger)
Indicates general cleanliness / dryness /
condition of insulation system
Indicates insulation system is capable of
higher voltage testing
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Insulation Resistance & Polarization Index

Suitability for service megger, per IEEE
43
@ 1 minute, > E +1 in Megohms
Expect 10 100 times that for clean, dry,
healthy windings

10 min. megger reading / 1 min. reading

Minimum PI for high voltage testing, per
IEEE 43 & 95
2.0 for class B and class F insulation
systems
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INSULATION RESISTANCE

2500

MEGOHMS

2000

1500

C-Left
B-Cent er
A-Right

1000

500

0
0.5

10

MINUTES

PI - Before Drying
INSULATION RESISTANCE

7000
6000

MEGOHMS

5000
4000

C-Left
B-Cent er

3000

A-Right

2000

1000
0
0.5

PI - After Drying
MINUTES

10

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Insulation Resistance & Polarization Index

If megger or PI is low:

Clean
Solvents / rags
Dry Ice (CO2) or corn cob blast
Dry
Heaters & dehumidifiers
Current through the winding
Bake/oven think desert
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DC Leakage Test
(Controlled Over Voltage)

Somewhat over-voltage test

Observe insulation characteristics upon
increasing voltage
Can possibly see failure prior to
occurrence & abort test

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DC Leakage Test
(Controlled Over Voltage)

Apply initial DC voltage

Increase voltage in steps
Hold at each step for a determined period
Monitor leakage current at each step
In a perfect world, E = I*R yields a
straight line when plotted
If current takes off exponentially, can
possibly stop test prior to insulation
failure
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DC LEAKAGE
70.00

MICROAMPS

60.00
50.00
40.00

A - Left
B -Center

30.00

C -Right

20.00
10.00
0.00
10

12

14

16

18

20

22

24

26

28

KV

DC Leakage - Bad

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DC Leakage Test
(Controlled Over Voltage)
Graded method (IEEE 95 Appendix A)
Initial voltage approximately DC equivalent
of 0.3 E or 10 KVDC
Each step increase = 20% of initial voltage
Time intervals per calculated N number
and IEEE 95 Table A1
Max. Voltage typically E x 2 (2E) DC with no
conversion multiplier
Typically, 10 KVDC for < 18KV / 15 KVDC for > 18KV

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High Voltage (Hi Pot) Testing

Proof test pass/fail, there is no in-between
DC or AC?
DC via IEEE 4, 95 & 56, ANSI C50.10
AC via IEEE 43 & 433 (.1 Hz.)
DC has proven adequate for decades
Some feel AC is better, but can not
quantify
DC value is 1.7 x AC value per IEEE 95
Recommended test value per IEEE 56
125% to 150% of rated line to line voltage
60 second duration

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Power Factor/Tip Up (Doble Test)

IEEE 286
Indicates voids/delamination of insulation
Sensitive on short conductors
Loses sensitivity as conductors are
connected in series
Track/trend data over-time for analysis

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Power Factor/Tip Up (Doble Test)

Measure Power Factor at low AC voltage
(25% phase to ground, below PD levels)
Measure power factor at higher voltage
(100% phase to ground)
Calculate difference in % = % Tip Up

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General Acceptance Criteria for Power

Factor and PF Tip Up (Doble Test)
Insulation System

2KV %PF

% PF Tip-Up

Asphalt-mica

4.0 or less

2.0 or less

Epoxy-mica

1.0 or less

1.0 or less

Polyester-mica

1.0 or less

1.0 or less

1.5 or less

1.5 or less

Pre-1980 epoxy-mica
or polyester-mica, GE
Micapal, W Thermalastic

Power Factor/Tip Up (Doble Test)

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Resistance Temperature Detection

Devices (RTDs)
Isolate from
instrumentation
Measure resistance of
legs
Compare to each other
Compare to expected

Megger (500 volts)

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RTDs

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Electro Magnetic Core Imperfection

Detector (EL CID)

Performed in lieu of Ring Test

Applies 4% rated flux density
Measure current between
laminations
High current indicates shorted
laminations

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Core Ring (Loop) Test

Performed @ 80% - 95%
rated flux
Thermovision Camera
used to detect
temperature differential
W during rewind 5 C,
otherwise 10 C
GE - ~18 C

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Core Ring Test Prior

to Core Restack

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Core Ring Test After

Core Restack

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End Winding Resonance Frequency

Test (Bump Test)
Excite end winding with calibrated,
accelerometer equipped hammer
Monitor response via accelerometer
Investigate amplitude & frequency of
response
Modify as required:
Add stiffness
Add mass
Reduce stiffness

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End Winding Resonance Test

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Initial Bump Test Results

Radial

Tangential

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Tuning Endwindings 101

Like playing a guitar
Long overhang
Low res. freq.
Low pitch
Short overhang
High res. freq.
High pitch

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Endwinding Music
End windings & support system should work
together like a choir
Move together as one
No solo performances

Everyone should be on the same note

Same tune / same beat
In tune

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After Nose Ring Modification

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Final Bump Test Results

(After Endwinding Stiffening)

Radial

Tangential

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Why do we care about

EW movement?

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Other Stator Tests - Specialized

Surge Test
Partial Discharge
Online/Offline PD
Corona Camera
Corona Probe/TVA Probe

AC Hi Pot 60 Hz and .10 Hz

EMI Testing
Robotic Inspection
Acoustic Surveys
New technologies constantly in development

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Stator DC Testing Summary

Phase (Winding) Resistance
2.5 KV or 5 KV Insulation Resistance (Megger) &
Polarization Index (PI)
DC Leakage Test
Power Factor/DOBLE Test
High-potential Test (Hipot)
RTD Resistance & Megger
EL CID Test
Specialized testing (as reqd)

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Field Electrical Testing

Megger
Impedance
Winding Resistance
Pole Balance (if possible)
RSO - Repetitive Surge
Oscilloscope

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Megger Test
Most widely used test to assess the condition of the
field
Good Megger indicates dry winding, low contamination
and good insulation
Poor Megger indicates possible contamination, bad
insulation or a wet winding

20 Meg Ohms minimum (OEM standard) for a hipot.

IEEE 62.2 Section 8.1.4.2
One minute reading more important for fields.
PIs are typically around 1.25 for fields.

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Megger Test Setup

500 VOLT MEGGER
TIME (MIN.)

0.5
1
2
3
4
5
6
7
8
9
10
PI

RESISTANCE
(MEGOHMS)

940
1020
1080
1160
1180
1180
1200
1200
1200
1240
1240
1.22

Note: IEEE 56 Section 8.2.3 Use a 500 volt megger on fields to obtain a
polarization index (PI). A 500 volt megger will be used for fields rated 125
thru 500 volts.

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Low Megger
Clean collectors and retest
If still low separate collectors and retest
If still low tent the field and use heat and
dehumidifiers to dry
If still low after several days, the retaining
rings may have to come off and internal
cleaning performed

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AC Impedance Test
0 to 130V AC in 10 volt steps
Plot impedance curve measuring AC Volts
and Amps
Look for step changes in the curve
Step change indicates possible shorted
turns
No step change indicates no shorted turns
in static condition

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AC Impedance Testing

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Winding Resistance

Always corrected for 25C!!

Check against factory issued resistance
for this field
Check against previous test results
Change in resistance indicates
possible shorted turns Lower Resistance
Broken connections/loose studs Higher
Resistance

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Pole Balance Test

Apply a voltage across the collector rings
Measure from one collector ring to the pole
jumper
Measure from the other collector ring to pole
jumper
As a rule of thumb, voltages should be within 5%
The challenge in completing this test is to reach
under the retaining ring and to put a test lead on
the pole jumper.

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Shorted Turn Test (Recurring Surge

Oscilliscope)
RSO Testing Results Look Like This
Indicates Unbalance and Shorted Turn

No Shorted Turns

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