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Shorted Rotor Winding Turns

Detection in Salient Pole


Rotor Machines

Outline

Review salient pole rotor winding design


Insulation deterioration processes
Off-line and On-line testing and monitoring
Case studies

Off-line vs On-Line
Off-line

On-line

Machine out of
service
Expensive
No load
Cold winding
No vibration
Testing voltage
source required

Machine in operation
Inexpensive, saves
time
Normal operation
voltage, temperature
and vibrations
Does not require test
voltage source
Centrifugal force

Synchronous Machines
Rotor windings provide magnetic field
Windings provide ampere turns to develop
rated generator output within limits of voltage
and temperature
Electrical requirements of insulation minimal
Severe mechanical and thermal requirements
Rotor diameter up to 20 m, weight in hundreds
of tons

Cross section of 2 pole generator

N
S

Cross section of 4 pole generator

N S
S N

Cross section of 12 pole rotor


S

S
N

N
S

Salient Pole Synchronous Motor


Rotor

Hydro-generator Rotor

Turbo generator salient pole

Typical Laminated Rotor Pole Assembly

11

Rotor Pole

Turn voltages
Large turbo: 5 to 15 volts per turn
21,200 kVA 3600 rpm generator: 0.52 volts
per turn
63000kVA 100 rpm generator 0.16 volts per
turn
800 HP 1200 rpm motor: 0.098 volts per turn
Turn insulation can be subjected to high
transient voltages

Salient Pole Rotor Windings


High speed machines are 4-8 poles
Up to 100 poles on large slow hydros
Synchronous motors (salient pole rotors)
have lower starting currents than squirrel
cage induction motors
Three types of winding: wire wound, edge
wound and picture frame construction
Voltages: 125-400 V DC
14

Winding Insulation
Typical materials:
- pole piece insulation, wrapped or molded:
nomex, fiberglass/resin laminate
- Pole tips and rotor body: collars from high
strength glass/resin, slip planes on long
poles
- Pre-wound coils potted after fitting on pole
pieces
15

Multi-Layer Wire Wound Pole


Mainly for smaller high speed and larger
slow speed motors
Use rectangular magnet wire to create the
turns which are wound on to pole
Turn insulation is usually a polyamideimide film
Ground insulation used to separate the
turns from the rotor body
Entire pole dipped in or VPId with resin
16

Multi-Layer Wire Wound Pole

17

Strip-on-Edge Pole
For hydro generators and larger motors
Pole winding made from a continuous strip of
copper formed into a slinky or use rectangular
picture frames with brazed connections
Use strips of NomexTM or epoxy-glass laminates to
separate the turns resin bonded to conductors
Tape used at the top and bottom few turns to
increase creepage distances to pole body
Sometimes impregnate entire pole with resin, or
each pole winding is hot pressed to consolidate it.

18

Strip-on-Edge Pole

19

Rotor Winding edge wound

20

Rotor Winding picture frame

21

Rotor Winding Insulation


Aging Processes

Thermal
Electrical
Ambient
Mechanical
Deterioration processes normally take
many years (or even decades)

22

Thermal Aging
Overloading or high cooling air temperatures
Inadequate cooling from poor design,
manufacture or poor maintenance
Use of materials having inadequate thermal
rating
Over-excitation of rotor winding
Shrinkage of bracing materials, looseness
Can result in both turn and ground insulation
failures
23

Thermal Cycling
Frequent starts and stops or wide variations in
load causing:
Relative movement between winding
components
Cracking at interfaces due to differential
expansion
Distortion of the winding conductors
Can cause both turn and ground insulation
failures
24

Repetitive Voltage Surges


High transient voltages can be induced on the
rotor winding from a static exciter or system
surges
Can cause turn to turn insulation faults

25

Contamination
Can be in the form of:
Moisture in cooling air
Oil from bearings
Conducting dust in atmosphere
Chemicals in atmosphere
A combination of these
Both turn and ground insulation failures from
tracking as well as winding overheating
Chemicals can degrade winding insulation to
cause failure
26

Strip on Edge Shorted Turns Due


to Contamination

27

Abrasive Particles
Abrasive particles such as coal dust, sand,
iron ore (grinding) can enter the cooling air
flow
Particles impinge on the rotor winding they
wear away the insulation
Can cause both turn and ground faults

28

Centrifugal Forces
Mechanical failure of the insulation can result
from:
High continuous or cycling centrifugal forces
during operation and starts/stops
These forces can cause rotor winding failures
from;
Inadequate intercoil bracing or shrinkage of
bracing materials in salient pole and round
rotor windings
29

Shorted Turn from Multilayer


Wire Wound Pole

30

Detection of Shorted Turns


Off-line
AC pole drop test, IR
RSO test
On-line
Increased bearing vibration
Increased excitation to achieve same MVA
Magnetic airgap flux monitoring

31

Relay Protection
If fitted, failure of the ground insulation is
normally detected by protective relaying that
gives an alarm or trips the machine
Failure of the turn insulation in one or more
spots does not cause a trip but may lead to
increased bearing vibration (at once per
revolution frequency) and limit the output
An increasing number of turn shorts over time
may indicate a higher risk of ground failure
Insulation may fail suddenly or gradually due
to aging
32

Pole Drop Test


Apply 120 Vac across field winding and
measure voltage drop across each pole
Measure the 60 Hz inductive impedance of
each pole to detect poles with fewer active
turns, and thus lower inductance
Poles with lower than average voltage
drop may have shorted turns
Shorts may disappear when rotor not
spinning, and vice versa
33

RSO Test
Recurrent Surge Oscillation
Low voltage (few volts), high frequency
(kHz range) surge injected into both ends
of the rotor winding
Time domain reflectometry based principle
Identical response indicates no shorted
turns

Magnetic Flux Monitoring to


Detect Shorted Turns
On-line method
Well established to detect shorted turns in
round rotor field windings
TF probe installed on a stator core tooth to
measure the induced voltage from the
magnetic flux as each pole passes the
probe

35

Total Flux Probe Installation

Kit connection
Key Phasor
Monitoring
shaft rotation
Power
supply 100240 VAC

RFA II/
Flux Trac II/
Guard

Flux Probe
Termination Box

Personal
Computer

TF probe
installed on a
stator tooth

Iris RFA II

Installation
TF Probe

TF Probe Termination
Box

Flux Monitor

TF Probe Detail
Machine
Sync Sensor

Local USB port for


configuration

Installation

Connection One Machine

150 m max.

Up to 4 Machines (Option)

Remote Communication

LAN

RJ45 port
Ethernet (LAN)
Off-the-shelf
converters
allowed
RotorFluxPro
SW included
Memory data
downloading
Data displaying

RFA Pro Software

Signal Analysis
High resolution magnitude and time A/D
conversion
Measure flux from each pole
Algorithms developed to reduce the
influence of rotor or stator asymmetry, air
gap variations, etc
If have a sensor to detect a specific
location on the shaft (key phasor), then
can identify the pole number
43

Three algorithms

-Compare pole to average of all poles


-Compare pole to its left and right neighbor
-Compare pole to poles of same polarity

Salient pole flux signal

Change of
Flux Pattern
with Load
change

Compare to average

Compare to adjacent

Use of two algorithms 1


Compare to average

Compare to adjacent

Air gap comparison

Use of two algorithms 2


Compare to average

Compare to adjacent

Shorted pole graph

Shorted pole identification

Non-circular rotor shape

Square rotor!

Four Pole Motor Result

Conclusions
-In general, disagreements between pole drop
test and on-line flux tests are possible due to
lack of centrifugal forces in pole drop test
- Rotor winding insulation is very reliable
However it does age due to thermal, mechanical
and contamination stresses
-Shorted turns can cause high bearing vibration
and may limit reactive power output

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