ELCID vs.

Loop Test:
Correlation of results in Assessing Stator Core
/By Brad McNamara and Peter Demers/
Routine testing of high voltage rotating machinery has always included
methods to detect insulation breakdown between the stator core
laminations. High powered Ring flux (or loop) and low powered ELCID
tests are the primary methods used by maintenance personnel for turbo
and hydro generators as well as large motors.
The Ring Flux test involves exciting the core to, or near to, the full
rated flux of the machine by means of several turns of a single phase
high voltage winding through the bore and around the outside of the
stator. The rated flux produces fault currents similar in level to those
that flow when the generator is in operation. Caution needs to be taken
as these currents can produce temperature rises which can cause further
damage because the generator cooling system is disabled.
Electromagnetic Core Imper-fection Detection (ELCID) was developed in
the late 1970's by the Central Electricity Generating Board (CEGB) in
the UK to enable it to readily test machines where a high power source
was not available. The technology is now well established in many parts
of the world as an easier means than the traditional ring flux test of
checking the integrity of interlaminar insulation for stator cores of
large rotating electrical machines. The ELCID test uses a similar
excitation winding but at a very low flux level, typically four percent
of rated flux. Hence the heat produced by faults is negligible and not
detectable, but the fault current is detectable by electromagnetic means
and it is this fault current, when scaled up to the appropriate rated
flux level, which would give rise to the local generation of heat and
associated hot spots.
*CASE STUDY*
In October 1997, GE Canada, Hydro Division, signed a contract with
Hydro-Qu?bec to refurbish five horizontal hydro-generators at the
Shawinigan 2 powerhouse. The Shawinigan 2 station is located in Quebec
and houses 8 units. Three were built in the early 1950's by Canadian
General Electric and are rated at 40 MVA, 11kV. The remaining five were
constructed between 1912 and 1914 by Westinghouse Company and are
coupled to two I.P. Morris horizontal Francis type turbines.
Hydro-Québec plans to uprate these five horizontal units from 15MVA,
6.9kV to 17 MVA, and 11kV. The contract began with Units 4 and 5,
scheduled to be rewound by the end of 1998.
In order to determine the remaining operational life of the cores
without the presence of any historical data, a decision was made to
conduct a full ring flux test in conjunction with an Electromagnetic
Core Imperfection Detection (ELCID) test on both units 4 and 5. Both
inspections would be conducted with the original winding in place.
Visually, the cores displayed no major surface damage. The customer
assumed the cores to be original with the exception of a partial
re-stack conducted in the mid-1960's during a full rewind. This
assumption would place the cores for Units 4 and 5 at 84 and 83 years
old respectively.
GE Canada subcontracted the manufacturer of the ELCID equipment, ADWEL
Inter-national Ltd. of Toronto, to assist in the ELCID analysis of the
cores. This also presented an opportunity to correlate the effectiveness
of the two test methods. The following is a brief account of the test
results and the actions taken for Unit 5.
The loop test was performed one day prior to the ELCID test. The stator
core was energized to a flux level of 0.835 Tesla and held for 45 to 60
minutes. Several locations were identified where the temperature was
5O¡C above the average core temperature. As an example, one area of slot
157 indicated a temperature rise of 15O¡C after 60 minutes. Figure 1
displays the thermographic image of that slot.
The following day an ELCID test was conducted using the Digital
ELCID-Model 601. The core was energized to 4 per cent of its rated flux
density using an excitation system of 20 series connected turns of 10AWG
wire and a current of 24 amps. Indications corresponding to the
previously located thermal hot spots were found for each of the damaged
areas. Figure 2 illustrates the ELCID trace for slot 157. The fault
current indicated greatly exceeds any acceptance criteria. It should be
noted that the EL CID test detected the fault instantaneously, while it
took 60 minutes for the loop test to fully identify the fault.
Based on the indications of both tests and the age of the core the
customer decided to completely replace the core iron. Prior to
completely removing the old core, the damaged areas were visually
located. Figure 3 shows the damage found at slot 157. It was determined
that the damage was caused by a coil groundwall fault which fused about
35 laminations located about 320mm from the exciter end of the core and
20mm below the core surface.
In order to develop a database, GE Hydro continues to apply the ELCID
method in addition to the conventional full flux ring test. This data
will provide useful correlation between core faults measured in mA with
the ELCID test and the expected real temperature rise at full flux
density. ADWEL International Ltd. continues to support the development
and application of the ELCID technology to hydrogenerators worldwide.
*SUMMARY*
The two forms of tests may be considered complementary to some extent
and the appropriate method will often be dictated by the prevailing
circumstances. Advantageous benefits of the ELCID include reduced
downtime, ease of use and safety for both machine and personnel.
Recently, the tendency to reduce major outages has given rise to ELCID
tests being carried out without removal of the rotor, where Ring Flux
tests are not possible. This is sometimes achieved by the removal of one
or two poles and the rotor then rotated to allow inspection of the
complete machine.
Studies of the correlation between the test results of both methods
provide a basis for confidence in ELCID test effectiveness itself and
also for continued monitoring of earlier Ring Flux detected faults.
Brad McNamara is with ADWEL International Ltd. Pierre Demers is an
Electrical Engineer with GE Hydro's RMU Team at the Generator Division
in Montreal. *ET*
------------------------------------------------------------------------
More Forums At The Electricity Forum Home Page
<http://www.electricityforum.com>
The Electricity Forum
Copyright 1999, The Electricity Forum. All rights reserved.