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Unconventional Diagnostic Methods for Testing Generator Stator Windings

Article  in  IEEE Electrical Insulation Magazine · September 2009

DOI: 10.1109/MEI.2009.5276075

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 F E A T U R
Unconventional Diagnostic Methods for
Testing Generator Stator Windings
Key Words: dielectric polarization, dielectric losses, frequency domain analysis, rotating machine insu-
lation testing, partial discharges
Introduction
The technical diagnosis of electric machines is a necessary
tool for condition evaluation and risk assessment. Normally,
condition- and risk-based maintenance strategy is applied to
high-value power equipment such as generators [1]. The aim of
the technical diagnostics is to detect any anomalies in the electri-
cal insulation system. In several standards there exist specifica-
tions for the test procedure and evaluation of the results. Some-
times additional recommendations have been applied as criteria
for acceptance or replacement.
The standard procedure for testing the electrical insulation
system of generator stator windings involves measurement of
the insulation resistance and the dielectric dissipation factor (tan
δ), and analysis of the partial discharge (PD) activity. Sometimes
a withstand test (Hipot) is applied. Visual inspection should also
be made along with the measurements.
These tests are carried out following specified routines and
procedures. The insulation resistance is measured according to
IEEE  43 [2] for dc, and tan δ according to IEEE 286 [3] for
ac. The partial discharge activity is investigated following IEEE
1434 [4] and IEC 60270 [5]. Test voltages are not specified in
these standards; however, rotating machines are usually tested at
their operating voltages.
The aim of this paper is to compare the results of conven-
tional methods for testing the insulation of generator stators with
those of recently developed, so-called, unconventional methods.
More specifically, insulation resistance, tan δ, and partial dis-
charge activity are compared.
Test Object and Measuring Equipment
The work was performed on-site on several hydro-generators,
and in the laboratory on stator bars. The results for one particular
generator are presented in this paper. It was commissioned in
1994 in a storage power station in the south of Austria, and is
rated at 20 MVA and 6.3 kV. The insulation system is a global
vacuum pressure impregnation (VPI) system with continuous
groundwall insulation. This winding is constructed with an inner
and outer corona protection system. The glow-protection var-
18 0883-7554/07/$25/©2009IEEE
E A R T I C L E
Christof Sumereder, Michael Muhr
Graz University of Technology, Austria
Michael Marketz, Christian Rupp
KELAG, Austria
Michael Krüger
OMICRON, Austria
Innovative diagnostic methods pro-
vide detailed information on the con-
dition of high voltage generator sta-
tor windings.
nish at the winding heads leads to a constant voltage drop, which
should reduce the probability of surface discharges. The on-site
measurements were made at the beginning of the annual routine
maintenance of the generator. (Diagnostic measurements were
made every three years on older generators and every five years
on new generators). Visual inspection of the winding showed
little pollution and normal signs of wear.
The following equipment was used for the measurements:
• transportable transformer with compensation and
electronic regulation, type AC resonance test system
350 kVA, 30-50 kV
• resonance test system with integrated capacitance mea-
suring device, type CPC, 100V-12 kV
• dielectric response analyzer, type DIRANA
• dc insulation tester 5 kV, type MIT 520
• loss factor and capacitance measuring device, type
LDV-6
IEEE Electrical Insulation Magazine
 • partial discharge measuring device, type LDS-6
• partial discharge measuring device, type MPD 600
Insulation Resistance vs. Dielectric
Response Measurement
The procedure for measuring the insulation resistance can be
found in [2]. A dc test voltage which depends on the rated volt-
age of the windings is applied to the totally depolarized winding
as a step function for 10 minutes. Because of various factors, the
resulting current decreases at a rate determined by the condition
of the insulation system. The total current has four components,
namely absorption, conduction, leakage, and charging of the ca-
pacitance of the winding. The latter can usually be neglected.
The leakage component is influenced by the surface condition
and humidity of the end windings, whereas the conduction com-
ponent depends on the volume resistance of the groundwall in-
sulation, and therefore temperature is an important factor. Fi-
nally, the absorption component is driven by the polarization
mechanisms in the solid insulation system.
What information on the condition of the windings can we
extract from conventional insulation resistance measurements?
Consider first the polarization index (PI). According to [2], the
ratio between the resistance measured 10 min and 1 min after
application of the dc voltage should be greater than 2.0. This re-
quirement is based on the rate of decay of the dominant leakage
and conduction components of the total current with time. Dry
and clean insulation systems have higher PI values. It has been
shown [6] that new windings can show larger PI depending on
the choice of material, construction of the field grading, and the
use of corona protection tape in the end windings.
The dryness of winding insulation can be evaluated using the
procedures outlined in [7] and [8]. The time constant τ10 of the
insulation system is given by
τ10 = R10 × C0,2 (1)
where R10 is the insulation resistance measured after 10 minutes,
and C0,2 is the capacitance of the winding measured at 20% of
the rated voltage.
Figure 1 shows that τ10 decreases approximately exponential-
ly with increasing temperature. The dryness border was defined
empirically, using on-site generator measurements [7].
To verify the dryness of the winding system, an unconven-
tional dielectric response measurement was made. Normally,
such measurements are used to determine the water content of
paper-oil insulation systems in transformers [9] or cables [10].
Polarization-depolarization current (PDC) and frequency do-
main spectroscopy (FDS) measurements were made. The advan-
tages and disadvantages of these methods have been discussed
in [11] and [12]. An innovative algorithm [13] applies FDS at
high frequencies and PDC at low frequencies, yielding a plot
of tan δ as a function of frequency in much less time than that
required for other methods.
The results of the combined FDS/PDC measurements are
presented in Figure 2. The dotted lines represent the PDC data
transformed from the time to the frequency domain. The FDS
method was used at frequencies above 0.1 Hz.
How can the above data be evaluated? There are no published
standards for dielectric spectroscopy measurements on dry or
humid generator windings. Only a few dielectric response inves-
tigations on the influence of humidity on generators have been
published [14], [15]. The results show that tan δ over the rel-
evant frequency spectrum is a more reliable dryness indicator
than PI, and that the ratio of the capacitances measured at 50 Hz
and 10 mHz can be as high as 10 for wet windings.
In order to study further the influence of the relative humid-
ity (RH) of the cooling air, a series of tests was carried out on

Figure 2: On-site tan δ values for RR asphalt (blue) and VPI

Figure 1: Insulation time constant τ10 of stator windings as a resin (red) generator insulation, as a function of frequency, ob-
function of winding temperature ϑSLOT [8] tained using FDS (solid) and PDC (dotted) measurements:

September/October 2009 — Vol. 25, No. 5 19


Figure 3: Temperature and humidity dependence of tan δ for
generator bars, as a function of frequency: lower blue line:
25°C at 27% RH, upper blue line: 25°C at 54% RH, lower
green line: 35°C at 21% RH, upper green line: 35°C at 54%
RH, lower red line: 45°C at 17% RH, and upper red line: 45°C
at 52% RH
Figure 4: Tan δ for humid and dry generator bars, as a func-
tion of frequency. Green and red line: dry conditions. Blue line:
90% RH, indicating a dominant surface resistance (all mea-
surements at 35°C)
Figure 5: Parallel and series resonance test circuit
20 IEEE Electrical Insulation Magazine
spare bars under laboratory conditions. The bars were stored
in a climate chamber and measurements were made at several
predetermined temperature and humidity values. Figure 3 shows
the results of the PDC and FDS measurements. Tan δ falls ap-
proximately exponentially with increasing frequency; earlier
investigators [16], [17] reported an exponential increase with
rising temperature. A small difference between very dry bars
(humidity < 20%) and medium dry bars (humidity ≈ 50%) was
observed. The tan δ values at net frequency for dry bars were ap-
proximately 4% lower than those measured at high humidities.
It will be seen that tan δ varies smoothly with frequency in all
samples; perhaps the influence of volume resistance is dominant
for RH values under approximately 60%. The surface resistance
is more important at high humidity values [18]. To investigate
the behavior at high RH the humidity of the air in the climate
chamber was increased to 90%. It was observed that tan δ in-
creases significantly at low frequencies (see Fig. 4).
In Figure 4, tan δ values for dry and very humid conditions
are shown. The gradient of the high humidity plot is much great-
er than that under dry conditions. (Tan δ at 50 Hz is about 0.018
up to 54% RH, but 0.068 at higher humidity). Because resin
insulation systems are not hygroscopic, the generator bars can-
not absorb large amounts of water vapor. Thus, the increase in
tan δ with increasing humidity can only be due to an increased
surface leakage current.
Insulation Testing: Parallel Resonance System
(Fixed Frequency) Versus Series Resonance System
(Variable Frequency)
Test systems utilizing series and parallel resonance are com-
mercially available. The problem with series resonance circuits
is that the test frequency depends on the capacitance of the ob-
ject being tested. For this reason a compensation device consist-
ing of additional parallel capacitors has to be installed in order to
bring the prescribed test frequency close to 50/60 Hz. In Figure
5, the equivalent circuits of parallel and series resonance sys-
tems are shown.
Figure 6: Tan δ for the 20MVA/6.3kV generator at 50 Hz, as a Figure 8: Tan δ for the 20MVA/6.3kV generator at 62 Hz, as a
function of test voltage. Black line: all phases in parallel. Col- function of test voltage.
ored lines: each phase separately.

Conclusions drawn from measurements at frequencies differ-

ing significantly from the grid frequency may not be valid at the
grid frequency. In [19] and [20], two generators were investigat-
ed using a series resonance system, but check measurements at
grid frequency were not carried out. It is known that tan δ varies
with frequency, possibly because of the design and materials of
the insulation systems.
A direct comparison between both test systems was carried
out on the generator chosen for the present study. Normally tan δ
is measured while the test voltage is raised to 120% of the rated
voltage in 10 to 20% steps. If the values vary smoothly, the in-
sulation system is considered to be in good condition. Systems Figure 9: The dependence of tan δ on test frequency
aged by operation usually show a change in slope at the partial
discharge inception voltage (PDIV). Because of ionization ef-
fects at inhomogeneities in the groundwall insulation, PD causes Before the measurements with the series test circuit were be-
additional dielectric losses, which are detected. gun, the resonance behavior of the whole generator winding was
A typical result is shown in Figure 6. For voltages up to 50% recorded, in order that the correct frequency compensation could
of the rated voltage, no PD occurs and tan δ varies smoothly. be applied. In Figure 7, the resonance curve of the winding and
At higher voltages, PD occurs and tan δ increases more rapidly. the source is shown. The resonance frequency is 62 Hz.
Single windings show almost identical behavior. The results are The voltage behavior of the winding at 62  Hz is shown in
below the limits specified in the standard [3], and therefore the Figure 8. Up to the rated voltage, the behavior is very similar to
winding may be considered to be in good condition. that at 50 Hz, the deviation being less than 1%.

Figure 7: Resonance behavior of winding and voltage source Figure 10: Delta tan δ of one phase as a function of test volt-
age: red dotted line at 50Hz, blue line at 62Hz

September/October 2009 — Vol. 25, No. 5 21


Figure 11: Wiring diagram for PD measurement (upper: con-
ventional; lower: multi synchronous)
Figure 12: Results of PD measurement. Left: single-mode system fingerprint. Right: multi-mode system fingerprint.
22 IEEE Electrical Insulation Magazine
Table 1. Results of PD Measurements at rated voltage
QIEC [pC] Neutral Point Network Point
Single mode system 2.121 1.995
Multi mode system 4.485 2.423
Tan δ was measured over the range 30 to 400  Hz. The re-
sults are shown in Figure 9. The highest gradient occurs at low
frequencies, indicating that tan  δ varies rapidly near the grid
frequency and therefore the data at the test frequency must be
corrected.
An important parameter for evaluation of the condition of a
stator winding is the power factor tip-up (delta tan δ), defined
as the increase in tan δ between measuring intervals. Figure 10
shows the results for one phase of the tested generator at 50 and
62 Hz. It can be seen that the tip-up is not dependent on the test
frequency.
Partial Discharge Measurement: Single Mode
Versus Synchronous System
The conventional partial discharge test system generates the
measuring signal by using a coupling capacitance and trans-
forming the analog signal into a quadripole. (A quadripole is
a measuring impedance which converted the decoupled current
pulses into equivalent voltage signals). The test circuit complies
with IEC 60034-27, as specified in IEC  60270 or IEEE 1434.
Normally the coupling capacitance is connected in parallel be-
cause of the fixed grounding of the generator stator.
During on-site PD measurements of generators, the windings
are investigated on both sides, i.e. at the neutral point and at the
winding line ends. For this reason, conventional PD measure-
ments of each phase have to be done separately [21]. Using a

Figure 13: Three-phase amplitude relation diagram.
recently developed PD test system [22], a synchronous measure-
ment of several quadripoles is possible [23]; thus the signal from
the beginning and end of the winding can be obtained in one
measurement. In the present test series, the generator was mea-
sured using both systems, i.e., the conventional and the multi-
sensor device. The standard frequency limit of conventional
broadband test systems is in the range 100 kHz to 1 MHz.
In Figure 11, the schematic wiring diagram of each PD mea-
surement circuit is shown. A coupling capacitor CKX (2 nF) is
necessary for each quadripole. In the multi-synchronous system,
all coupling units are connected to the PC by a fiber optic cable,
so that fewer grounding problems arise.
In Figure 12, the test results of phase U at the rated volt-
age are shown: on the left is the fingerprint of the single-mode
system, and on the right that of the multi-mode system. Partial
discharge activity at rated voltage is expressed in pC (the QIEC
values shown in Table 1).
The fingerprints are very similar. Both show a normal distri-
bution of internal discharges from delaminated insulation. The
PD patterns at the network side show low level internal and slot
discharge activity. Some typical PD patterns are presented in
[24]–[26].
The QIEC levels on the network side are similar, but differ
considerably at the neutral point (Table 1). The discrepancy is
probably caused by differences in bandwidth, equivalent circuit,
and calibration signal.
One of the advantages of the synchronous test system is the
three-phase amplitude relation diagram— 3PARD [26]. Using
this feature, the results of up to three PD sensors can be dis-
played as synchronous vectors on one phase diagram. The ori-
gin of PD can then be located easily by zooming into a specific
region of the frequency spectrum. By energizing the generator
with a single-phase source, and connecting the other phases in
parallel with the neutral point (see Fig. 11), a phase shift caused
by a distributed capacitance can also be observed using the
3PARD diagram.
September/October 2009 — Vol. 25, No. 5 23
An example of the 3PARD diagram is given in Figure  13,
which was obtained from an off-line measurement. The sen-
sors are connected to the three phases U, V, W (network side)
and the PDs are measured synchronously. It can be seen that
the highest PD level is close to Phase V (dark red color area).
In an advanced application, single areas can be scanned and the
frequency spectrum analyzed. In this way, the type of PD can be
determined and its origin located.
SUMMARY
This paper presented a comparison of different methods of
measuring insulation resistance and tan δ (dissipation factor),
and of documenting partial discharge activity. The measurements
were made on several service-aged generators. The results for
one in-service generator, obtained between service inspections,
are discussed in detail.
Comparing classical insulation resistance measurements and
the dielectric response behavior in the frequency domain, good
agreement is found. With the insulation time-constant, the dry-
ness can be determined relatively. In the case of resin-impreg-
nated insulation systems, additional investigations are required
to determine the humidity absolutely.
The determination of tan  δ using various test systems and
measuring methods was carried out on-site. Because tan  δ is
frequency- and temperature-dependent, the results of series
resonance circuit measurements must be modified by correcting
for the difference between the measurement frequency and the
power frequency.
The results obtained using various PD-test systems depend
on bandwidth and the circuit configuration. The multi-synchro-
nous system has the significant advantages that the PD activity
at several points can be monitored in one measurement, and the
three-phase amplitude relation diagram makes it easy to identify
the PD source. However, the calibration process is lengthy, so
little time is saved overall, and a full set of quadripoles and cou-
pling capacitors is needed for each channel.
REFERENCES
[1] M. Marketz, C. Rupp, and H. Egger, “Risk-based maintenance and
replacement strategy for generators in storage power plants,” presented at
Hydro 2008, Ljubljana, Slovenia.
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ing Machinery, IEEE Std 43-2000, 2000.
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of Electric Machinery Stator Coil Insulation, IEEE Std 286-2000, 2000.
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 [10] W. S. Zaengl, “Dielectric spectroscopy in time and frequency domain for Institute of High Voltage Engineering and System Management.
HV power equipment (transformers, cables etc.),” presented at Int. Symp. He has worked on new technologies for insulation materials as
High Voltage Engineering 2001, Bangalore, India.
well as cryogenic systems. Currently, his fields of special inter-
[11] M. Koch, S. Tenbolen, M. Krueger, and A. Kraetge. “Improved moisture
analysis of power transformers using dielectric response methods,” pre- est are on-site diagnostics of hydro generators, and maintenance,
sented at MatPost07–3rd European Conference on HV & MV Substation reliability engineering, and life-time investigations of insulation
Equipment, Lyon, France. systems. He is a member of ÖVE and CIGRE.
[12] A. Bouaicha, I. Fofana, M. Farzaneh, A. Setayeshmehr, H. Borsi, E.
Gockenbach, A. Beroual, and N. T. Aka, “Dielectric spectroscopy tech-
niques as quality control tool: A feasibility study,” IEEE Electr. Insul.
Mag., vol. 25, no. 1, pp. 6–14, Jan./Feb. 2009
[13] A. Akbari, A. Setayeshmehr, M. Farahani, H. Borsi, and E. Gockenbach, Michael Muhr graduated in electrical engi-
“A software technique for transforming dielectric data from time domain
neering in 1971. He received his doctorate
to frequency domain for insulation diagnosis of power transformers,” pre-
sented at Int. Symp. High Voltage Engineering 2007, Ljubljana, Slovenia. in technical science from Graz University
[14] S. A. Bhumiwat, “Application of polarisation depolarisation current of Technology in 1977, and is presently
(PDC) technique on fault and trouble analysis of stator insulation,” pre- Head of the Institute of High Voltage Engi-
sented at CIGRE SCA1&D1 Joint Colloquium, 2007, Gyongju, Korea.
neering and System Management, Head of
[15] S. A. Bhumiwat, “Practical experiences on condition assessment of stator
insulation using polarisation/depolarisation current techniques,” presented the Test Institution for High Voltage Engi-
at CIGRE Session 2008, Paris, France. neering Graz Ltd., and Vice Rector for Ac-
[16] C. Sumereder and M. Muhr, “Humidity absorption of generator bars,” ademics. He has received many honors for
presented at Int. Conf. Properties and Applications of Dielectric Materials
his research work, including Doctor h.c.
2006, Bali, Indonesia.
[17] A. Küchler, “Hochspannungstechnik”, page 265, 3rd ed. Berlin [u.a.]: from University Pilsen. He is a member of IEC, IEEE, CIGRE,
Springer, 2009, ISBN 978-3-540-78412-8. and ÖVE.
[18] M. Muhr, R. Schwarz, and C. Sumereder, “Evaluation of the dissipation
factor under different environmental conditions,” presented at Int. Symp.
High Voltage Engineering 2007, Ljubljana, Slovenia.
[19] W. Hauschild, P. Coors, J. Weidner, and P. Gradinarov, “Diagnostische
Prüfungen an Ständerwicklungen großer rotierender Maschinen mit AC Michael Marketz studied electrical engi-
Resonanzprüfsystemen variabler Frequenz,” presented at ETG-Fachta- neering at Graz University of Technology
gung Diagnostik Elektrischer Betriebsmittel 2004, Köln, Germany.
before joining the department of Power
[20] H. Michitsch and J. Spiegelberg, “High voltage test of large rotating
machines for commissioning and for diagnosis on the installation side,” System Operation, Kelag in 1999. He re-
Elektrizitätswirtschaft, vol. 104, no. 17–18, pp. 62–70, 2005 ceived his Ph.D. in 2003, and currently is
[21] T. Strehl, “On- and off-line measurement, diagnostics and monitoring head of the department of Power Plant Op-
of partial discharges on high-voltage equipment,” presented at HV Test-
eration and Maintenance.
ing, Monitoring and Diagnostics Workshop 2000, Alexandria, VA, Sep.
13–14, 2000
[22] K. Rethmeier, B. Vandiver, A. Obralic, W. Kalkner, and R. Plath, “Ben-
efits of synchronous multi-channel PD measurements,” presented at IEEE
Conf. Electrical Insulation and Dielectric Phenomena 2007, Vancouver,
Christian Rupp studied Electrical Engineer-
BC, Canada.
[23] R. Goffeaux, M. Krecke, B. Comte, M. Cottet, and B. Fruth, “Dielectric ing at Graz University of Technology. Since
test methods for rotating machine stator insulation inspection,” presented 2005, he has been working with Kelag in
at IEEE Conf. Electrical Insulation and Dielectric Phenomena 1998, the department of Power Plant Operation
Atlanta, GA.
and Maintenance. His special field of inter-
[24] Rotating Electrical Machines - Part 27: Off-Line Partial Discharge
Measurements on the Stator Winding Insulation of Rotating Electrical est is condition assessment and risk evalua-
Machines, IEC 60034-27-2006, 2006. tion of power system equipment
[25] Knowledge Rules for Partial Discharge Diagnosis in Service, CIGRE
Brochure 226, Paris, France: CIGRE, 2003.
[26] W. Kalkner, A. Obralic, A. Bethge, and R. Plath, “Synchronous 3-phase
partial discharge detection on rotating machines,” presented at Int. Symp.
High Voltage Engineering 2005, Beijing, China. Michael Krüger studied Electrical Engi-
neering at the Technical Universities of
Aachen and Kaiserslautern. He received
his Ph.D. in the field of cable testing at the
Christof Sumereder graduated in electrical
Technical University of Vienna. Currently
engineering from Graz University of Tech-
he is head of Engineering Services Primary
nology in 1997. After three years of indus-
Testing at OMICRON. He is a member of
trial experience he received his doctorate in
VDE, IEEE, and CIGRE.
technical science with honors in 2003, and
is presently an Assistant Professor at the

24 IEEE Electrical Insulation Magazine

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