Proceedings of POWER2008

ASME Power 2008

July 22-24, 2008, Orlando, Florida, USA

POWER2008-60167

VERIFYING SUITABILITY FOR SERVICE WITH EMI DIAGNOSTICS

James E. Timperley P. E.
IEEE Fellow
Doble Engineering
Columbus, Ohio, USA

ABSTRACT

This paper provides examples of conditions found with

nuclear plant electrical equipment by the application of EMI
(electromagnetic interference) Diagnostics. This is an on-line
test that can detect a wide variety of defects in motors,
generators, power cables transformers and isolated phase bus.
There is no interruption to service and no risk to the system
while data is collected.

Photo 2
Connection to Collect Generator EMI Data

Photo 2 shows the RFCT application on the generator

stator grounding transformer. This is the preferred location to
collect generator system data.

INTRODUCTION

Many nuclear power plants are near or have exceeded the

Photo 1
original equipment design 30 year service life. Even with an
Connection to Collect Motor EMI Data
excellent operating history, accurate condition assessment for
continued service is important for life extension. EMI
Photo 1 shows the temporary placement location of a RFCT
Diagnostics is an on-line test that has been used since 1980 to
(radio frequency current transformer) to collect EMI data from
provide information on the condition of motors, generators,
this CWP motor.
isolated phase bus, power cables and transformers without
interruption to service. No design change is required to

1 Copyright © 20xx by ASME

implement the test. There is no risk to operation since no direct
connection to any energized circuit is required for data
collection. EMI data collection passive, no signal is injected
into the system under investigation. Information is processed
by computer and the analysis expert based. Trending of data is
not required: A first evaluation can offer maintenance
recommendations by comparison to an existing data base of
several thousand tests.
EMI stands for Electromagnetic Interference and is a term
used by communications engineers to describe unwanted radio
frequency signals generated by electrical devices. EMI
Diagnostic of rotating machines and associated electrical power
systems is an extension of the methods and test standards
applied since the 1920’s to measure and identify various radio
frequencies generated by defects in power equipment. The
application of EMI Diagnostic techniques for the in-service
evaluation of large generators began in 1980; in 1985 13 kV
and 4 kV motors were routinely evaluated. There have been
over 7,000 tests conducted on some 500-machine designs.
The EMI testing standard EPRI, TR-102323, REV.3 does
not apply to EMI Diagnostics of power equipment. This guide
is for measuring EMI activity usually from electronic devices
and is not used for maintenance planning of components like
motors and isolated phase bus. The international CISPR
standards are used for collecting data. Data analysis is expert
based.
The radio frequency (RF) spectrum of interest ranges from
50 kHz to about 100 MHz. Defects in motors, generators,
cables and transformers generate radio frequency signals or
EMI when defects develop in insulation or conductors. The
resulting patterns are classified as arcing, corona, partial
discharges or random noise. There are a wide variety of defects
that may develop and numerous combinations of EMI patterns
that can result. Ambient signals such as utility power line
carriers (PLC), AM, FM and TV stations are also present.
These transmitters have a fixed frequency and amplitude and
serve as valuable benchmarks for verifying data and trending
future data.
PDA AND EMI SIGNALS
Partial Discharge Analysis (PDA) is a time domain
technique that relies on accurate measurement of each
discharge event. Amplitude, polarity, power frequency phase
relationship, apparent charge transfer and event count rate are
important characteristics for accurate analysis. When a PD
occurs there is also an electromagnetic (EM) wave produced
that travels away from the discharge location. This is what EMI
Diagnostics measures.
PDA requires a design change to install permanent high
voltage couplers or “slot couplers” in a generator. Only
machine stator defects are monitored. Other PD sources are
treated as “noise” and discarded.
PDA by definition does not measure arcing where there is
current flow. This limits the technique to classifying only
insulation defects and excludes conductor defects such as loose
connections. Many mechanical defects such as a motor mis-
alignment and shaft seal rubs also result in arcing and generate
EMI that PDA can not detect or identify.
EMI Diagnostics is a frequency domain analysis of those
damped oscillations that result from each PD impulse or arcing
event. Every EMI pattern is unique for each type of defect.
EMI can be either radiated or conducted from the defect
location. That part of the energy that is conducted can be
measured with a radio frequency current transformer (RFCT).
Data are presented on a logarithmic scale to better represent
both low and high values on one chart. Amplitudes from 0.1
microvolts to 100 millivolts with frequencies ranging from 50
kHz to 100 MHz on an EMI signature plot are not unusual.
REQUIRED EQUIPMENT
The precision RF voltmeter used to measure EMI is NIST
traceable and in full compliance with CISPR #16 and ANSI
C63.2 standards, with a variety of detector time constants and
intermediate frequency bandwidths. It is capable of displaying
activity from 50 kHz to 100 MHz with a dynamic range of 100
dB.
Data is collected from the temporary placement of a split
core RFCT around the power feed to the motor, the generator
neutral lead or a machine safety ground. The process is
completely passive. No signal is generated by the test
equipment. No direct connection to any energized system is
necessary. This avoids the numerous high voltage connections
required with PDA techniques. There is no design changed
required to collect data.
It is basic that the act of measuring does not change the
quantity being monitored. All successful diagnostic techniques
must be non-intrusive. The current probe method of obtaining
an EMI signature satisfies this requirement.
EMI Diagnostics is essentially the capture and
classification of all signals present at a given measurement
location. EMI patterns are evaluated in the frequency domain
as well as visually (what does the discharge look like) and
audio (what does the discharge sound like). A typical survey
will require 30 minutes to one hour to complete at each
location.
2 Copyright © 20xx by ASME
 Data is usually collected annually or every 18 months as a
part of a condition based maintenance program. Perhaps 80%
of the components tested need no maintenance. Only 5% 13.2 kV 6000 hp
Circ. Water Pump Motor C
require attention at the next outage. Identifying this 80% that Comparison 2000-2005
1000
does not require outage resources is as important as locating
those components that need attention. EMI Diagnostics is Random noise
&
Partial discharges
& Partial discharges
SCR noise Corona &
sufficiently sensitive to detect many problems in the early

Microvolts (Quasi-Peak)
Corona
100
12-18-00
stages.
10

10-05-05

1
Pd's &
Corona

0.1
0.01 0.1 1 10

Frequency (MHz)

Curve 2
Motor C after Repairs

Motor C in Curve 2 had extensive stator repairs in 2001.

The EMI signature for 2005 verifies these repairs were keeping
Photo 3
partial discharges below levels present in 2000. Activity
Connection to Collect Transformer EMI Data
increases in 2006 prompted a stator rewind in 2007.

Photo 3 shows the usual RFCT location on a transformer

tank safety ground.
10000 4000 volt 2000 hp
Feed Water Pump Motors
Microvolts (Quasi-Peak)

1000 Cyclic discharges (Rotor bars )

EXAMPLES Bearing discharges OB motor bearing

100 Slip noise &

Curve 1 shows EMI Signature curves for two circulating process noise

water pump motors. The “B” motor is in good condition with 10

no maintenance needed. The “A” motor indicates there is a
problem with the power cable connections. This motor had 1
BFP Motor B

recently been installed. An inspection in the terminal box to BFP Motor A

check for loose bolted connections was recommended. 0.1

0.01 0.1 1 10

Frequency (MHz)
10000 4000 volt 4000 hp
Circ. Water Pump Motors
Curve 3
1000
Microvolts (Quasi-Peak)

SCR noise
Motor “B” Has Broken Rotor Bars
Slip noise &
process noise Partial discharges
100 in motor lead box
Sleeve bearing problems and broken rotor bars can be
10
expected during the service life of large induction motors.
CWP Motor B Motor “B” in Curve 3 has developed both problems. A hand
1 CWP Motor A held EMI detector is used to isolate the location of each defect.
SCR noise
Motor “A” has no requirement for maintenance.
0.1
0.01 0.1 1 10

Frequency (MHz)

Curve 1
EMI Signatures of Two CWP Motors

3 Copyright © 20xx by ASME

 4160 V 1750 hp 1786 rpm
Condensate Booster Pump Motors
22 kV 1447 MVA 1800 r/min
1000
Corona Generator
Quasi-Peak (microvolts)

1000
100 AM

Microvolts (Quasi-Peak)
Exciter SCR stations
noise
* Random
10
Corona 100 * noise
Resonance

Gap
Noise
1 2 Middle Condensate Booster 10 11-05-01
2 North Condensate Booster
12-03-03
0.1
0.01 0.1 1 10 1 * Developing wet stator bar
Frequency (MHz)

0.1
Curve 4 0.01 0.1 1 10 100
Comparison of Clean and Dirty Motors Frequency (MHz)

Even in the clean environment of a nuclear power plant Curve 6

motor windings collect dirt. Knowing when to clean a stator is A Generator with One Wet Stator Bar
essential to a good condition based maintenance program. The
2 North motor (red) in Curve 4 has some dirt accumulation but
the 2 Middle machine (blue) needs cleaning at the next outage. One particular series of generators is prone to developing
water leaks and wet stator bar insulation. Curve 6 shows the
1200 MW 1800 r/min subtle increases in the EMI signature due to one wet bar near
Generator Power Down Test
the neutral. Wet insulation develops the same random noise
100 pattern as surface contamination. With this design of generator
Quasi-Peak (microvolts)

the characteristic frequencies of wet insulation are near 1 and

10 MHz. During the next outage water was removed for the
winding and one phase had a low insulation reading to ground.
10
A bottom stator bar near the neutral was found to be wet and
was replaced.

1 1171 MW 710 MW 558 MW

Mean = 18.2 uV Mean = 11.9 uV Mean = 9.14 uV
800 MW Nuclear Plant
Generator
1000
0.1 1 10
Quasi-Peak (microvolts)

Arcing carbon shaft

Frequency (MHz) 100 grounding brushes

Curve 5 10
This Machine Has Loose Stator Bars
1 Exciter
noise
Tightening a generator stator winding can be expected
during the normal service life. Curve 5 is an example of a 0.1
generator power down test. When a stator winding is tight 0.01 0.1 1 10 100
changes in the load will not change the EMI signature. If a
stator winding is loose then EMI amplitude follows the load. Frequency (MHz)
The generator above has a reduction of EMI mean levels as the
load is reduced. This indicates the stator winding is loose and Curve 7
should be tightened. However the question was could Minor Shaft Ground Sparking
rewedging be postponed for two cycles while major turbine
work was performed? The answer was yes, rewedging could be The generator in Curve 7 has minor sparking at the shaft
postponed with minimum risk. The activity at full load did not grounding brushes. Carbon brushes tend to glaze over and are a
indicate severe looseness was present. Rewedging was high maintenance option for shaft grounding. Cleaning the
postponed to a later outage and has recently been completed.

4 Copyright © 20xx by ASME

brushes was recommended. Bearing damage will result from
shaft currents if the shaft is not grounded properly. Nuclear Plant
1000
NCC Pump Motors B&C

Microvolts (Quasi-Peak)
100
11-10-04 NCC Motor B
Slip noise Moderate corona
1,200 MW Generator with severe arcing Test cables
10000 of shaft grounding braids 10 "B" Motor
Microvolts (Quasi-Peak)

1000 Power
Line
With Arcing 1
Carriers
Shaft Grounding Braid
100
11-10-04 NCC Motor C

10 0.1
0.01 0.1 1 10
W/O Arcing
1 Frequency (MHz)

0.1
0.01 0.1 1 10 100 Curve 10
Frequency (MHz) Defective 4 kV Power Cable

Curve 8 There have been a few cases where power cable problems
Severe Shaft Grounding Problems have been detected while testing a motor. In Curve 10 the “B”
motor has high cable corona levels. There should be no
The generator in Curve 8 had a new shaft grounding measurable partial discharge activity on shielded 4 kV cables.
system installed. The arcing was severe after a few weeks Additional cable testing was recommended.
operation. Equipment misoperation resulted from the extremely
high levels of EMI that were generated. A new shaft grounding
assembly was recommended.

Emergency Diesel Generator Div 2 vs Div 1

10000
Microvolts (Quasi-Peak)

1000 Noise
spike

100
Exciter noise Random
noise
10 Div 2 Diesel Gen.
11-10-04
Div 1 Diesel Gen.
1 09-08-04

0.1
0.01 0.1 1 10
Frequency (MHz)

Curve 9 Curve 11
Signatures of Emergency Generators Wet 4 kV Power Cable
Curve 9 shows the comparison of two emergency diesel In Curve 11 motor “B” has no indications of any
generators. Data was collected during the routine load test. problems, the local AM radio stations have higher levels than
Data was collected from a generator frame ground since the system related PD activity. However the cable tunnel for the
winding neutral was not accessible. No problems were “A” motor is flooded and there are high cable corona levels
expected and none were detected. Most of the spectrum is across the spectrum.
dominated by the exciter power electronics. If winding
problems were present they would be seen at frequencies above
1 MHz.

5 Copyright © 20xx by ASME

 1,100 MW
1100 MVa 22kV 1800 r/min Nuclear Generator
Generator 1000 Exciter End
100
New
Quasi-Peak (microvolts)

Hydrogen

Quasi-Peak (microvolts)
Isolated phase bus Seal Rub
discharges
Stator related activity
100 Exciter
October, 1996 Diode
10 Transients

10

June, 2001
1
August, 2002
1
June, 1996 Microsparking
in Isolated Phase Bus
0.1 0.1
0.01 0.1 1 10 100 0.01 0.1 1 10 100
Frequency (MHz) Frequency (MHz)

Curve 12 Curve 14
Developing Isolated Phase Problems An Exciter End Seal Rub

In generator in Curve 12 developed severe isolated phase During an annual EMI Diagnostic the generator in Curve 14
bus discharges after bus maintenance was performed in 1996. had an increase in activity around 8 MHz. The hand held EMI
EMI levels at frequencies above 10 MHz had increased. A bus detector located the source as the generator exciter end
inspection and review of past activities was recommended. hydrogen seal. The seal was replaced during the next outage.
There was severe pitting on the brass seal from the shaft
currents that had caused the high EMI levels.
1400 MVA 24kV 1800r/min
Generator
1000
345 / 13 kV
Quasi-Peak (microvolts)

Start-up Transformers
Isolated Phase
100 Gap Discharges
Comparison
October 9, 1996
PL AM
Carriers Stations
10 1000
Microvolts (Quasi-Peak)

Corona & Micro-sparking

July 22, 1997 from Defective
Unit #2 (Solid Line) 345 Disconnect Switch
1 100
October 9, 1996
Unit #2 (Dashed Line)
0.1 10
Unit 1 startup xfmr
0.01 0.1 1 10 100
Unit 2 startup xfmr
Frequency (MHz) 1

Curve 13 0.1
Before and After Bus Repairs 0.01 0.1 1 10 100
Frequency (MHz)
The generator shown in Curve 13 is at the same location as
the generator in Curve 12. In 1996 there were only minor bus Curve 15
discharges noted around 30 MHz. These disappeared when the A Defective 345 kV Disconnect Switch
system was retested nine months later. No maintenance was
recommended. Transformer hardware problems can also be detected with
EMI. In Curve 15 the partial discharge source was a loose
connection on a high side disconnect switch of the #2
transformer. This was verified with an ultrasonic scan and
repaired during the next outage.

6 Copyright © 20xx by ASME

 Nuclear Generator With Arcing
GSU Transformer Shield Ground [3] Timperley, J. E., “EMI and Generator Condition Monitor
OK in 98 Arcing in 99 GSU Winding
100
Shield Ground Application,” Technical presentation at the Eighth EPRI
Quasi-Peak (microvolts)

Arcing
Turbine/Generator Workshop and Vendor Exposition,
1998
1999 August 2003, Nashville, TN.
10
[4] Allen, J. D., and Timperley, J. E., “Scheduling Power
Generator Activity
Plant Maintenance on EMI Diagnostics,” Coal Gen, August
2003, Columbus OH.
1

[5] J. E. Timperley, D. A. Klinect, E. Koegler ,“Comparison of

PD and EMI Techniques to Detect Electrical Aging of a Water
0.1
0.01 0.1 1 10 100 Cooled Stator Bar”, IEEE EIC/EMCW Conference, October
Frequency (MHz) 2001, Cincinnati, OH,

Curve 16 [6] Timperley, J. E., “Focus Maintenance Resources and

Internal transformer EMI Source
Curve 16 shows the internal arcing of a loose shield inside
a GSU transformer. This condition had developed between the
1998 and 1999 tests. Dissolved gas analysis of the transformer
oil confirmed an internal problem existed. During the next
outage the oil was removed, the loose connection located and
repaired.
Improve Turbine Generator System Reliability with On-Line
EMI Diagnostics,” ASMI paper PWR 19121, ASME
International Joint Power Conference, June 2001, New
Orleans, LA.
[7] J. E. Timperley, E. Keith Chambers, Locating Defects in
Large Rotating Machines and Associated Electrical Systems
Through EMI Diagnostics, Thirty Fourth Session of CIGRE, ,
paper 11-311, Paris, France, Sept. 1992

CONCLUSION

EMI Diagnostics is an expert based technology that can be MOTOR CONDITIONS IDENTIFIED WITH EMI
an important part of a nuclear plant condition based
maintenance program. A wide variety of equipment problems 1. Dirty stator windings
can be detected. Data can be trended to track deterioration rates 2. Loose windings in slots and end-arms
or to measure success of repairs. The power electrical systems 3. Broken rotor bars
are monitored under normal load conditions with no 4. Synchronous motor field ground
interruption to operations. No design changes are needed to 5. Rotor not set on magnet center
collect data. 6. Frame had loose foundation (soft foot)
7. Wiped sleeve bearings
8. Defective outboard bearing insulation (shorted)
ACKNOWLEDGMENTS 9. Bearing oil seal rub,
10. Exciter drive shaft weather seal rub
The author appreciated the help of John Allen, George 11. Coupling misalignment with driven gear box, pump, fan
Karayianopoulos, Stan Carter, and Dave Klinect for their 12. Defective or missing coupling insulation
assistance in the preparation of this paper. 13. Circulating currents in driven pumps
14. Magnetized gear box shafts / gears
REFERENCES 15. Loose neutral connections
16. Loose crimp / bolted line connections
[1] Timperley, “Generator Condition Assessment Through EMI 17. Loose surge / power factor capacitor connections
Diagnostics,” ASMI paper PWR 2008-60166, ASME Power 18. Abrasive erosion of stator windings
2008, July 2008, Orlando, Florida. 19. Defective motor lead insulation
20. Detect wet power cables
[2] Timperley, J. E., Michalec, J. R., Moore W., Moudy, H., 21. Detect 13 kV cable stress cone deterioration
Hutt, J., “Rewind and Core restack of Conesville #5 22. Verify correct maintenance was or was not performed
Generator,” ASMI paper PWR 2004-52145, ASME Power
2004, March 2004, Baltimore, MD.

7 Copyright © 20xx by ASME

GENERATOR CONDITIONS IDENTIFIED

1. Loose stator coils or bars SYSTEM CONDITIONS IDENTIFIED

2. Stator slot discharges from coating erosion
3. Partial discharges between phase groups 1. Loose BUS insulators or hardware
4. Loose endwindings or circuit rings 2. Broken or contaminated BUS insulators
5. Broken or loose ties / blocking 3. Stray Isolated Phase BUS currents
6. Winding contamination, oil, dirt, water 4. Foreign Metal Objects within Isolated Phase Bus
7. Foreign metal objects on stator winding enclosure
8. Field ground in generator or exciter 5. Loose connection on bus potential transformer
9. Arcing slip rings generator or exciter 6. Open Bus PT fuse
10. Loose exciter diode connections 7. Loose connection on surge capacitor
11. Exciter or voltage regulator stability problems 8. Loose transformer connections
12. Defective voltage regulator damping circuits 9. Loose internal shield in a generator breaker
13. Bearing currents, bearing wipe 10. Loose neutral grounding resistor connection
14. Shaft oil and hydrogen seal rub 11. Loose disconnect switch hardware
15. Loose flux shield grounding bolt 12. Loose connection in ground grid
16. Sparking shaft grounding system

8 Copyright © 20xx by ASME