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IEEE Std 1665™-2009
IEEE Guide for the Rewind of

Synchronous Generators, 50 Hz
and 60 Hz, Rated 1 MVA and Above
Sponsor
Electric Machinery Committee

of the
IEEE Power & Energy Society
Approved 11 September 2009

IEEE-SA Standards Board
Abstract: 50 Hz or 60 Hz synchronous generators driven by diesel engines, steam turbines,
combustion gas turbines, and hydro-turbines are covered in this guide. The drive may be direct or
through a gear box or other device that permits different speeds for the prime mover and the
generator. The guide generally applies to the stator and rotor of generators with rated outputs of
1 MVA and above. The guide does not address machine auxiliaries or the excitation system.
This guide will provide the generator Owner with insight into the considerations that are
necessary when rewinding or refurbishing a generator. Particular emphasis is placed on the
complete rewind of the stator and rotor.
Keywords: cylindrical-pole rotor, insulation, rotor rewind, salient-pole rotor, stator rewind,
synchronous generator
The Institute of Electrical and Electronics Engineers, Inc.

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PDF: ISBN 978-0-7381-6064-1 STD95970

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Introduction
This introduction is not part of IEEE Std 1665-2009, IEEE Guide for the Rewind of Synchronous Generators, 50 Hz
and 60 Hz, Rated 1 MVA and Above.
At the turn of the 21st century, many of the generators used by electric utilities and industrial plants had
reached their design life. Because of today’s economics, many of these generators may be called upon to
supply reliable service for an additional 20 to 30 years, or more. Any generator Owner intending to
significantly extend the life of the generating plant by rewinding and refurbishing the generator should
address three key areas: economics, developing a technical specification, and performance upgrades
through better materials/design.
A comprehensive economic study should be carried out (for the plant as well as the generator) before the
investment of significant resources. This should include plant load forecasts, reserve margins, new capacity
plans, cost benefit analyses, operating costs, capital costs, and continued reliability/availability.
Once a financial decision has been made to rewind, it is essential that a technical specification be
developed. The technical specification should establish a clear understanding between the Owner and the
Vendor, with regard to what the final product will be. Doing so creates an understanding of the level of
performance and reliability expected by the Owner/user and what is required in the manufacturing process
to achieve it. In addition, to ensure a quality product is achieved, specific tests, measurements and
inspections that are to be required in the manufacturing process need to be clearly spelled out. The
technical specification is a means for these requirements and expectations to be stated.
New materials, major component replacement, and other design changes may also affect the life extension
decision. For example, the development of better insulation systems has been ongoing for many years in
the industry. The ability to uprate the nameplate output with these new materials may make rewind and
refurbishment cost effective.
Throughout this guide the term “generator” has been used, instead of “rotating machinery,” in order to
simplify the text. Many of the items contained herein are also appropriate for large synchronous motors.
However, this guide does not address machine auxiliaries or the excitation system; nor does it address the
generators found in modern wind turbines. The reader is directed to the latest version of the IEEE 421™
series of standards for excitation systems.
Notice to users
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iv
Copyright © 2010 IEEE. All rights reserved.
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may be obtained from the IEEE Standards Association.
v
Participants
At the time this guide was submitted to the IEEE-SA Standards Board for approval, the Generator
Subcommittee/Generator Rewind Working Group had the following membership:
William H. Bartley, Chair

James R. Michalec, Vice Chair
John Amos James Grant Beant Nindra

Partic Saber Azizi Gary Heuston James A. Oliver
Ray Bartnikas Richard Huber Michel Rioual
Stefano Bomben Haran Karmaker Kim Robinson
Michael Brimsek Geoff Klempner Lori Rux
Andrew Brown Laurent Lammare Jill Smith
Doug Conley Jim Lau Gregory Stone
Ian Culbert Clyde Maughan Meredith Stranges
Matthew Davis William McDermid Remi Tremblay
Jim DeHaan Bert Milano James E. Timperley
Mario Dumouchel Charles Millet Thomas R. Wait
Elton Floyd Glenn A. Mottershead Robert Ward
Nancy Frost Nils Nilsson Chuck Wilson
The following members of the individual balloting committee voted on this guide. Balloters may have
voted for approval, disapproval, or abstention.
William J. Ackerman Gary Heuston Jerry Murphy

Michael Adams William B. Hopf Michael S. Newman
William H. Bartley David Horvath Nils Nilsson
Thomas Bishop James Jones Alvaro Portillo
William Bloethe Innocent Kamwa Madan Rana
Steven Brockschink Joseph L. Koepfinger Charles Rogers
Andrew Brown Chung-Yiu Lam Bartien Sayogo
Gustavo Brunello Daniel Levin Douglas Seely
Weijen Chen William Lockley Ahmed El Serafi
Matthew Davis William McBride Gil Shultz
Gary L. Donner William McDermid James E. Smith
Donald Dunn Don Mclaren Gary Stoedter
James Dymond Nigel Mcquin Gregory Stone
Gary Engmann Gary Michel Wayne Timm
Rostyslaw Fostiak Charles Millet John Vergis
Randall Groves Glenn A. Mottershead Chuck Wilson
Bal Gupta James Wilson
vi
When the IEEE-SA Standards Board approved this standard on 11 September 2009, it had the following
membership:
Robert M. Grow, Chair

Thomas Prevost, Vice Chair
Steve M. Mills, Past Chair
Judith Gorman, Secretary
John Barr Alexander Gelman David J. Law

Karen Bartleson Jim Hughes Ted Olsen
Victor Berman Richard H. Hulett Glenn Parsons
Ted Burse Young Kyun Kim Ronald C. Petersen
Richard DeBlasio Joseph L. Koepfinger* Narayanan Ramachandran
Andy Drozd John Kulick Jon Walter Rosdahl
Mark Epstein Sam Sciacca
*Member Emeritus
Also included are the following nonvoting IEEE-SA Standards Board liaisons:
Howard L. Wolfman, TAB Representative

Michael Janezic, NIST Representative
Satish K. Aggarwal, NRC Representative
Lorraine Patsco
IEEE Standards Program Manager, Document Development
Soo Kim
IEEE Standards Program Manager, Technical Program Development
vii
Contents
1. Overview .................................................................................................................................................... 1
1.1 Scope ................................................................................................................................................... 1
1.2 Purpose ................................................................................................................................................ 1
1.3 Cautions............................................................................................................................................... 2
2. Normative references.................................................................................................................................. 2
3. Definitions; acronyms, and abbreviations; and special terms..................................................................... 3

3.1 Definitions ........................................................................................................................................... 3
3.2 Acronyms and abbreviations ............................................................................................................... 4
3.3 Special terms........................................................................................................................................ 4
4. General issues, strategies, and objectives for rewinding ............................................................................ 5

4.1 General ................................................................................................................................................ 5
4.2 Future operating modes ....................................................................................................................... 5
4.3 Reliability issues.................................................................................................................................. 5
4.4 Competitive bidding ............................................................................................................................ 6
4.5 Generator capability issues .................................................................................................................. 7
5. Generator stator winding considerations .................................................................................................... 9

5.1 General ................................................................................................................................................ 9
5.2 Winding design considerations............................................................................................................ 9
5.3 Stator bar construction......................................................................................................................... 9
5.4 Winding groundwall insulation ......................................................................................................... 11
5.5 Generator end winding and connection rings support ....................................................................... 12
5.6 Slot support systems .......................................................................................................................... 13
5.7 Series/phase electrical connections and insulation ............................................................................ 13
6. Generator rotor considerations ................................................................................................................. 14

6.1 Cylindrical rotors............................................................................................................................... 14
6.2 Salient-pole rotors.............................................................................................................................. 17
7. Writing the technical specification ........................................................................................................... 19

7.1 General .............................................................................................................................................. 19
7.2 Objective............................................................................................................................................ 20
7.3 Project description ............................................................................................................................. 20
7.4 Definitions ......................................................................................................................................... 20
7.5 Scope ................................................................................................................................................. 20
7.6 Work conditions ................................................................................................................................ 21
7.7 Foreign material exclusion ................................................................................................................ 21
7.8 Deliverables ....................................................................................................................................... 22
7.9 Commercial issues............................................................................................................................. 22
7.10 Attachments ..................................................................................................................................... 22
8. Testing...................................................................................................................................................... 22
8.1 General .............................................................................................................................................. 22
8.2 Stator core.......................................................................................................................................... 22
8.3 Stator winding.................................................................................................................................... 23
8.4 Rotor winding .................................................................................................................................... 26
8.5 Other tests.......................................................................................................................................... 27
viii
Annex A (informative) Bibliography ........................................................................................................... 28
Annex B (informative) Glossary of commonly used generator terms .......................................................... 30
Annex C (informative) Generator components and auxiliaries .................................................................... 39

C.1 Stator frame and core [turbo-generators] .......................................................................................... 39
C.2 Stator frame and core [hydrogenerators]........................................................................................... 40
C.3 Generator monitoring instrumentation .............................................................................................. 43
Annex D (informative) Stator rewind information ....................................................................................... 47

D.1 Coil construction............................................................................................................................... 47
D.2 Stator winding insulation .................................................................................................................. 47
D.3 End winding support (for hydrogenerators)...................................................................................... 52
D.4 Stator slot support systems ............................................................................................................... 52
D.5 Vibration concerns............................................................................................................................ 53
Annex E (informative) Cylindrical rotor rewind information ...................................................................... 54

E.1 Rotor forgings ................................................................................................................................... 54
E.2 Rotor winding.................................................................................................................................... 56
Annex F (informative) Salient-pole rotor rewind information ..................................................................... 62

F.1 Shaft .................................................................................................................................................. 62
F.2 Rotor construction ............................................................................................................................. 62
F.3 Rotor windings .................................................................................................................................. 63
F.4 Rotor electrical connections .............................................................................................................. 64
Annex G (informative) Information typically supplied in a specification by Owner or Vendor .................. 65
Annex H (informative) Typical preparations for a rewind specification...................................................... 68

H.1 General.............................................................................................................................................. 68
H.2 Stator rewind..................................................................................................................................... 69
H.3 Rotor rewind ..................................................................................................................................... 71
Annex I (informative) Typical stator rewind specification for turbo-generators.......................................... 72

I.1 Description of the project ................................................................................................................... 72
I.2 Machine data ...................................................................................................................................... 73
I.3 Owner’s responsibility (as required) .................................................................................................. 73
I.4 Requirements...................................................................................................................................... 73
Annex J (informative) Typical rotor rewind specification for turbo-generators........................................... 78

J.1 Description of the project................................................................................................................... 78
J.2 Scope of work and supplies................................................................................................................ 80
J.3 Supplemental work conditions ........................................................................................................... 83
J.4 Job progress ....................................................................................................................................... 84
J.5 Deliverables ....................................................................................................................................... 84
J.6 Commercial........................................................................................................................................ 85
J.7 Attachments ....................................................................................................................................... 85
Annex K (informative) Typical stator rewind specification for hydrogenerator .......................................... 86

K.1 Description of the project ................................................................................................................. 86
K.2 General requirements........................................................................................................................ 89
K.3 Material requirements ....................................................................................................................... 91
K.4 Required information........................................................................................................................ 92
K.5 Tests.................................................................................................................................................. 93
K.6 Warranty ........................................................................................................................................... 94
ix
Annex L (informative) Typical rotor rewind specification for hydrogenerators .......................................... 95
L.1 Description of the project.................................................................................................................. 95
L.2 Rotor rim/spider cleaning.................................................................................................................. 96
L.3 Material requirements and workmanship .......................................................................................... 97
L.4 Testing............................................................................................................................................... 97
L.5 Required information ........................................................................................................................ 98
L.6 Shipping ............................................................................................................................................ 98
L.7 Warranty............................................................................................................................................ 98
x
IEEE Guide for the Rewind of
Synchronous Generators, 50 Hz
and 60 Hz, Rated 1 MVA and Above
IMPORTANT NOTICE: This standard is not intended to ensure safety, security, health, or
environmental protection in all circumstances. Implementers of the standard are responsible for
determining appropriate safety, security, environmental, and health practices or regulatory
requirements.
This IEEE document is made available for use subject to important notices and legal disclaimers. These
notices and disclaimers appear in all publications containing this document and may be found under the
heading “Important Notice” or “Important Notices and Disclaimers Concerning IEEE Documents.”
They can also be obtained on request from IEEE or viewed at http://standards.ieee.org/IPR/
disclaimers.html.
1. Overview
1.1 Scope
The general parameters for this guide apply to 50 Hz or 60 Hz synchronous generators driven by
reciprocating engines, steam turbines, combustion turbines, and hydro turbines. The guide generally applies
to the stator and rotor of generators with rated outputs of 1 MVA and above. The guide does not address
machine auxiliaries or the excitation system.
1.2 Purpose
This guide will provide the generator Owner with insight into the considerations that are necessary when
rewinding or refurbishing a generator. Particular emphasis is placed on the complete rewind of each of the
components of the stator and rotor.
1
IEEE Std 1665-2009
IEEE Guide for the Rewind of Synchronous Generators, 50 Hz and 60 Hz, Rated 1 MVA and Above
1.3 Cautions
CAUTION
Hazardous materials warning: On some generators there may be hazardous materials such as asbestos,
lead carbonate, or lead paint. As an example, many Vendors used asbestos in the stator or rotor insulation
system. Some hydrogen cooled units may contain lead carbonate. The presence of lead carbonate is due
to a reaction of the water, carbon dioxide, and lead in the solder used to manufacture the coolers. In such
cases, abatement work, cleaning, and disposal of hazardous materials shall be performed according to
appropriate government regulations. The Vendor should provide the Material Safety Data Sheets (MSDS)
for all materials used on site for a rewind. Excess material, brought in by the Vendor, should be removed
by the Vendor at completion of the rewind. However, on most projects, the Owner is responsible for
removal of hazardous materials.
2. Normative references
The following referenced documents are indispensable for the application of this document (i.e., they must
be understood and used, so each referenced document is cited in text and its relationship to this document is
explained). For dated references, only the edition cited applies. For undated references, the latest edition of
the referenced document (including any amendments or corrigenda) applies.
ASTM D1868, Standard Test Method for the Detection and Measurement of Partial Discharge (Corona)
Pulses in Evaluation of Insulation Systems. 1
IEEE Std 4™, IEEE Standard Techniques for High-Voltage Testing. 2,3
IEEE Std 43™, IEEE Recommended Practice for Testing Insulation Resistance of Rotating Machinery.
IEEE Std 62.2™, IEEE Guide for Diagnostic Field Testing of Electric Power Apparatus—Electrical
Machinery. 4
IEEE Std 67™, IEEE Guide for Operation and Maintenance of Turbine Generators.
IEEE Std 95™, IEEE Recommended Practice for Insulation Testing of AC Electric Machinery (2300 V and
Above) with High Direct Voltage.
IEEE Std 115™, IEEE Guide: Test Procedure for Synchronous Machines.
IEEE Std 286™, IEEE Recommended Practice for Measurement of Power-Factor Tip-Up of Electrical
Machinery Stator Coil Insulation.
IEEE Std 393™, IEEE Standard for Test Procedures for Magnetic Cores.
1
ASTM publications are available from the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken,
PA 19428-2959, USA (http://www.astm.org/).
2
The IEEE standards or products referred to in this clause are trademarks of the Institute of Electrical and Electronics Engineers, Inc.
3
IEEE publications are available from the Institute of Electrical and Electronics Engineers, 445 Hoes Lane, Piscataway, NJ 08854,
USA (http://standards.ieee.org/).
4
This IEEE standards project was not approved by the IEEE-SA Standards Board at the time this publication went to press. For
information about obtaining a draft, contact the IEEE.
2
IEEE Std 1665-2009
IEEE Std 522™, IEEE Guide for Testing Turn Insulation on Form-Wound Stator Coils for Alternating-
Current Rotating Electric Machines.
IEEE Std 1043™, IEEE Recommended Practice for Voltage-Endurance Testing of Form-Wound Bars and
Coils.
IEEE Std 1310™, IEEE Recommended Practice for Thermal Cycle Testing of Form-Wound Stator Bars and
Coils for Large Generators.
IEEE Std 1434™, IEEE Guide to the Measurement of Partial Discharges in Rotating Machinery.
IEEE Std 1553™, IEEE Standard for Voltage-Endurance Testing for Form-Wound Coils and Bars for
Hydrogenerators.
IEEE Std C37.102™, IEEE Guide for AC Generator Protection.
IEEE Std C50.12™, IEEE Standard for Salient-Pole 50 Hz and 60 Hz Synchronous Generators and
Generator/Motors for Hydraulic Turbine Applications Rated 5 MVA and Above.
IEEE Std C50.13™, IEEE Standard for Cylindrical-Rotor 50 Hz and 60 Hz, Synchronous Generators Rated
10 MVA and Above.
3. Definitions; acronyms, and abbreviations; and special terms
3.1 Definitions
For the purposes of this document, the following terms and definitions apply. The IEEE Standards
Dictionary: Glossary of Terms & Definitions 5 and the glossary in Annex B should be referenced for terms
not defined in this clause. Note that Annex B contains a practical glossary of commonly used terminology
for generators. The Annex B glossary is included in this guide as an informative annex, for information
only, and is not an official part of the standard.
bar: In electric machinery, the terms “bar” and “coil” are not interchangeable. A bar is usually considered
to be half of a coil, and is most often applied to single-turn coils.
bonding: The term “bonding,” with respect to electrical insulation, refers to a physical bonding, or
structural uniting between two physical materials.
hydrogenerator: The term hydrogenerator refers to a synchronous ac generator having salient-pole rotors
and driven by a hydraulic turbine or waterwheel. (Also known as hydroelectric generator.)
interlaminar insulation: The stator core is made up of many thin sheets of electrical grade steel
(laminations), which are insulated from one another to reduce eddy current losses between the laminations.
mil: One thousandth of an inch.
5
The IEEE Standards Dictionary: Glossary of Terms & Definitions is available at http://shop.ieee.org/.
3
IEEE Std 1665-2009
re-insulation: The removal and replacement of all of the machine’s insulation (or a portion thereof). The
winding insulation comprises all of the insulating materials that envelope the current-carrying conductors
and their component turns and strands and form the insulation between them and the machine structure, and
includes the armor tape, the tying cord, slot fillers, slot groundwall insulation, support rings, pole body
insulation, and rotor-retaining ring insulation.
rewind: The disconnection and removal of the generator stator winding, support systems, and temperature
monitoring detectors for the purpose of replacing this assembly, in all or part, with new. On rotors, rewind
means the removal of the winding and replacement of all insulating materials, and in some cases the copper
of the coils.
Roebel bar: Stator bars manufactured with Roebel copper strand transpositions.
strand insulation: The stator coil/bar conductor is made up of multiple strands, which are insulated from
one another in order to reduce eddy current loss effects.
turn insulation: On multi-turn coils, the strand insulation is not usually sufficient to withstand the turn-to-
turn voltage stress. Addition insulation in the form of taping is applied to the turns by hand or machine to
give adequate strength to hold the voltages of normal service and the impulse voltages of abnormal events.
This insulation also serves as part of the groundwall insulation.
3.2 Acronyms and abbreviations

ETPC: electrolytic tough pitch copper
FME: foreign material exclusion
MSDS: material safety data sheets
NDE: non-destructive examination
OEM: original equipment manufacturer
OFC: oxygen-free copper
OFHC: oxygen free, high conductivity
PD: partial discharge
RF: radio frequency
RTD / TC: resistance temperature detector or a thermocouple
VPI: vacuum pressure impregnation
3.3 Special terms

In this guide, the following special terms and definitions apply.
Bidder: Throughout this guide the terms “Bidder” and “Bidders” have been used to represent the potential
Vendor that is bidding on the generator rewind work. The Vendor could be an original equipment
manufacturer (OEM), or an independent repair firm.
4
IEEE Std 1665-2009
Owner: Throughout this guide the terms “Owner” and “Owners” have been used to represent the generator
Owner /operator /user. It is typically, a utility, a municipality, or an industrial firm.
Vendor: Throughout this guide the terms “Vendor” and “Vendors” have been used to represent the
company that will conduct the generator rewind. This could be an original equipment manufacturer (OEM),
or an independent repair firm.
4. General issues, strategies, and objectives for rewinding
4.1 General
Many of the generators used by electric utilities and industrial plants have reached the end of their design
life. Because of today’s economics, many of these generators may be called upon to supply reliable service
for an additional twenty to thirty years, or more. In some cases, these old generators are being uprated in
order to deliver the additional power of a turbine rating increase. Presently there are no formal guidelines or
recommended practices on how to rewind a large ac generator. This guide should provide the generator
Owner with some insight into the many technical issues that are involved, when rewinding or refurbishing a
generator.
4.2 Future operating modes

There are several different operating modes for the aging generator, which can depend on the prime mover
constraints, the economics of load dispatching, and other technical and economic factors. These operating
modes include base loading, load following, load cycling, peaking, and in the case of pump storage units,
switching between generating and motoring in short periods of time. A change in operating mode can occur
as newer machines displace older machines in the dispatching order. It is not uncommon, for example, for a
machine to be base loaded when new and then later become load-following or load cycling when older.
Obviously, any of the latter operating modes are more stressful to the windings than is base loading.
Therefore, any change of operating mode should be accounted for in the requirements specified for a
rewind. Frequently, a machine nearing the end of winding life is put into a last-on, first-off mode of
operation to extend life until a rewind can take place.
4.3 Reliability issues

Advancements in the area of insulating materials and composites allow significant reliability improvements
to be achieved by replacing older materials in the generator that are near the end of their useful life. In
addition to replacing the generator coils with new insulation systems, significant enhancements can be
obtained by upgrading the design of the winding support systems, or by improving the cooling arrangement
of the rotor. For example, the stator slot wedging system can be upgraded to a modern wedge and coil
packing design, thus reducing the potential for damage due to winding movement in the slot.
If the Owner is looking to upgrade the capacity, and/or increase efficiency, the designer may often take
advantage of the improvements in withstand voltage of modern dielectrics by placing more stress on these
dielectrics. This means that reliability is not always increased. There is a trade-off with capability and
efficiency. A winding may continue to operate with strand-to-strand shorts, but not with turn-to-turn faults.
In multi-turn coils, each conductor turn (i.e., bundle of strands), should be carefully insulated to prevent
short circuits between adjacent turns. Failure of the turn-to-turn insulation will rapidly cause machine
failure because high currents will circulate between the shorted turns, resulting in arcing and very high
temperature at the site of the short circuit. The arcing turn-to-turn fault will quickly melt the copper strands.
The heat will quickly destroy the groundwall insulation. In this light, on multi-turn coils one might want to
evaluate if additional turn insulation is warranted since turn-to-turn insulation failures are quite common.
5
IEEE Std 1665-2009
While this guide is focused on rotor and stator rewinds, it is important to consider other generator
equipment and auxiliaries that should be part of any major generator rebuilding project. Some of these
other items are as follows:
⎯ Control cabinets
⎯ Bearings and journals
⎯ Brushes, brush rigging, brush holders
⎯ Excitation system
⎯ Generator coolers
⎯ Generator bushings
⎯ Governors and their controls
⎯ Hydrogen seals
⎯ Stator frame
⎯ Surge arresters and surge capacitors
Please note that the above list is only a partial list of the many generator components and appurtenances.
This list is only for illustration, and neither purports to set forth all the generator components, nor implies
the importance of one component over another. Annex C contains a detailed discussion on the inspection
and testing of the generator’s vital components and auxiliaries. This discussion is included in this guide for
information only and is not an official part of the standard.
4.4 Competitive bidding

From an Owner’s perspective, a competitive bid for a generator rewind may be preferable to a single-
source procurement. However, it is imperative that the Owner ascertain that all Bidders are qualified and
capable of performing the required work. In a competitive bid situation, the original manufacturer may start
with an advantage, because the original manufacturer should have all the dimensions and design
information.
Other potential Bidders may need access to the machine in advance of the bids, to verify that their designs
can be implemented in the given machine, and to achieve more precision in their bids.
Unless it is specified in the bidding document, some Bidders may limit the rewind to replacement of the
stator coils/bars, while reusing many components such as the parallel rings, endwinding support, and
thermal expansion systems. Obviously the Owner can specify that all these items be replaced, but in so
doing, the Owner may incur an unnecessary significant cost increase. If re-using any components is an
option, the Owner’s bid specification should have stringent testing and acceptance requirements, to verify
that the old components are in optimum condition.
In a competitive bid situation, the outage duration, rather than the bottom line cost, may be the deciding
factor in selecting a rewind Vendor. In recent years, there have been major improvements in tooling and
techniques that have produced a significant reduction in the time needed to rewind a unit. If one Bidder’s
previous rewind experience is 45 days, and another is 30 days, the shorter duration in the outage can have
economic advantages. Owners may impose bonus and penalty clauses in the contract for timely outage
completion, but this may place enormous detrimental pressure upon the field crew that does the work.
6
IEEE Std 1665-2009
Large hydrogenerator rewind outages can take so long that it can become economically advantageous to
purchase a spare core and frame so all rewinds in a multi-unit plant can be performed elsewhere in the
powerhouse, and the actual outage reduced to an integrated frame, core, and winding assembly switch-out.
The Owner should have a good bid specification to ensure that all Bidders are meeting the same technical
requirements. In addition, the Owner should devise an evaluation process that compares the benefits of
design improvements and outage duration. Specific knowledge of the equipment is essential and this
standard may not provide that information.
4.5 Generator capability issues

There are many reasons why an Owner may need a generator rewind. A failure may have occurred; or the
insulation is in poor condition and near the end of its useful life. Quite often in these cases, the Owner will
elect to retain the same original generator design capacity or capability.
However, modern insulating materials provide an opportunity to design and manufacture coils/bars with
thinner ground wall insulation. This has two advantages: a) the thermal resistance of the groundwall is
reduced because of thinner material; and b) potential electrical uprate, due to the thinner material, which
allows more copper to be included in the winding. However, thinner ground wall designs may result in
higher partial discharge (PD) energy levels, which may reduce the winding life expectancy. Of course, the
opportunity will vary depending on the vintage and type of the original machine design. But, this
opportunity can create the erroneous impression that the complete machine has greater current capability
than before the rewind, simply because there is more copper. To avoid new source performance
requirement issues, it may be preferred that Bidders describe the benefits of additional conductor material
in terms of lower operating temperature and longer reliable life of the winding. The old resistance
temperature detector (RTD) temperatures cannot be used for margin increases in rating, as the thinner
insulation will show higher temperatures. The increase in rating has to be calculated by a design engineer.
4.5.1 Upgraded stator windings
When additional generator capability is desired (such as in the case of a concurrent turbine efficiency
upgrade), there are many more issues to be considered. Will the improved insulation system operate at an
MVA level that is consistent with the reactive needs of the power system? With no changes to the rotor, the
machine may operate at a higher power factor (closer to unity) and thus will produce less reactive power
(MVARs) at higher real power (MW) levels.
When rewinding a stator there may be an opportunity to improve the temperature class of the insulation
system. Older generators were equipped with windings typically having Class 130 (Class B) insulation. A
typical replacement winding today will have Class 155 (F) insulation that can operate continuously at
higher temperature. However, if the machine was originally designed to operate at Class 130 (B)
temperatures, there could be mechanical issues associated with an uprate to Class 155 (F). For example, the
risk of stator core buckling should be evaluated. Also, the allowable hotter stator temperature may have a
negative impact on the rotor winding insulation and the stator core lamination insulation. Therefore it is
quite common today for a rewind specification to call for the modern Class 155 (F) insulation, but to
operate within the Class 130 (B) temperature range.
Whenever the stator winding capability is to be increased, the generator shall still operate within the
restrictions of the generator’s capability curve. To assist the Bidders for this particular case, the Bidders
should be provided with nameplate data, capability curve, V-curve, and rotor resistance versus temperature
curve. The Bidders may also want slot dimensional data. Instead of the Owner providing the capability
curve and related data, it may be more desirable to have the Vendors submit ratings (a new capability
curve) based on what their winding designs are purported to achieve.
7
IEEE Std 1665-2009
In addition to stator and rotor windings, there are other related electrical components and systems that also
should be evaluated, to determine if they can operate in concert with an upgraded stator. Examples include
the following:
a) Prime mover capability

b) Generator bushings (current rating)
c) Generator current transformers (current rating)
d) Generator step-up transformers (MVA rating)
e) Generator isolated phase-bus-duct (current rating)
f) Generator switchgear or circuit breaker (current rating)
g) Generator neutral equipment (current rating and protection coordination)
h) Powerhouse grounding network (current rating)
i) Auxiliary equipment—reactor, bus bars, cables, switchgear and circuit breakers (current rating)
j) Protective systems (coordination, limiter, alarm, and trip settings)
k) Excitation system
l) Penstock limitations
m) Rotor mechanical structure, coupling, maximum speed /overspeed, torque, magnetic attraction
n) Generator collector ring ampacity (if so equipped)
NOTE—Please note that the above list is only a partial list of the many generator components and systems that should
be evaluated. This list is only for illustration, and does not purport to set forth all the generator hazards, nor to indicate
that other issues or hazards do not exist. 6
Any time that a machine is being uprated, some of the components may be operated closer to their design
margins. As a result, not only should protection systems be reviewed for setting changes, but also
additional state of the art protection systems should be considered for application. Reference IEEE Std
C37.102. 7
This is particularly true regarding the changeover from a rotating exciter to a static exciter. This is a major
upgrade/redesign that may require a fault study, a shaft torsional study, and major protective relay
modifications. Startup and shutdown sequences and procedures also will be impacted. A source for the
static exciter and associated protection and switching should also be provided. Standard operating
procedures and black start procedures will also have to be modified.
Prior to the replacement of an old rotating exciter with a static excitation system, the Owner should
evaluate the existing rotor insulation’s ability to withstand any field voltage surges that may be created by
the new system thyristors.
Obviously, it will be necessary to work more closely with the Bidders than in the case where no change is
planned in machine capability. Clause 5 offers some considerations for stator rewinds, and Annex D
provides some fundamental information on stator windings.
6
Notes in text, tables, and figures of a standard are given for information only and do not contain requirements needed to implement
this standard.
7
Information on references can be found in Clause 2.
8
IEEE Std 1665-2009
4.5.2 Rotor rewinds or reinsulation upgrades
The rotor may be upgraded with no change in the stator capability or in concert with a stator upgrade. In
either case, the goal of the rotor upgrade is usually to provide more reactive power (MVARs). Care should
be taken to coordinate with other electrical system components as described in 4.5.1. One important issue
that is occasionally overlooked is whether or not the excitation system can provide the power for the new
rotor capability.
Upgrading the rotor may also be coordinated with other rotor design changes. For turbo-generators, this
could include the installation of new retaining rings, made of 18% manganese and 18% chromium, (18Mn-
18Cr) to replace older designs such as 18Mn-5Cr retaining rings. In addition, all rotating components
should be carefully inspected and non-destructively examined (NDE), including the rotor forging. Clause 6
offers some considerations for rotor rewinds; and Annex E and Annex F provide some fundamental
information on generator rotors, and rotor windings. Design changes such as eliminating the ventilating
holes in magnetic retaining rings can be included.
5. Generator stator winding considerations
5.1 General
There are several components in a stator winding. In this clause, important considerations relating to each
of these components will be discussed, with the objective of providing the basis for the information
included in a stator rewind specification. Annex D contains a more detailed discussion on the construction
and materials found in a generator stator. Annex D is included in this guide for information only and is not
an official part of the standard.
5.2 Winding design considerations

There are some possibilities for the choice of the winding design. The objective of this clause is only to
give short descriptions of different aspects.
If the original winding design was made with multi-turn coils, in some cases (mainly hydrogenerators) it
could be possible to modify the design to utilize Roebel bars. One of the advantages of using Roebel bars is
minimizing the risk of a turn-to-turn failure. A Roebel bar is more easily removed than a coil. However the
Roebel bar winding is more expensive than a coil winding. If the change is made to Roebel bar, (and a
reduction of the number of parallel circuits), a review of the magnetic forces in the air gap is prudent. For
more information on Roebel bars, please see Annex D. The generator Owner should carefully analyze the
advantages and disadvantages of this aspect, particularly for a large generator.
If a stator winding is subject to circulating currents between parallel circuits, due to an electrical unbalance
or an air gap non uniformity, these currents between parallel circuits may affect the sensitivity of the split
phase protection, when each phase-end of the winding circuits is brought out of the machine through the
split phase current transformers. Depending on conditions, especially reactive loading, the relay sensitivity
could be increased or decreased
5.3 Stator bar construction

The copper used in coil construction is either oxygen free copper (OFC) or electrolytic tough pitch copper
(ETPC). Generally, oxygen-free copper is not used on air-cooled machines. The physical and electrical
properties of each are essentially the same. Since OFC has no oxygen present, it is better when brazing
9
IEEE Std 1665-2009
applications are specified. The chance of hydrogen embrittlement of the copper is lessened. The copper
wire is rectangular in shape and has rounded corners.
The strand insulation in all bar designs should be reliable and capable of withstanding design operating
temperature. Today, Class 155 (F) material is typically used. Since the voltage between individual strands
is small (less than one volt), this insulation can be thin. (For coils without internal transpositions, the
voltage from one side of the bar to the other may be in the order of 15 V, and a “vertical separator” is
sometimes used to control this voltage.)
Direct water-cooled windings will have either 100% hollow strands or a mix of solid strands and hollow
strands. The hollow strands are sized relatively large to allow for passage of water; the solid strands are
sized thin to reduce the eddy-current losses. The hollow strands are typically copper, but other alloy
material is often used on some water-cooled windings to reduce corrosion problems.
Crucial considerations in stator coil/bar construction include the following:
a) No strand or turn shorts.

b) Good coil/bar shape control.
c) PD-resistant turn insulation on multi-turn coils.
d) Well-bonded and integrated coil/bar for mechanical stability.
e) On water-cooled bars, a strand header that is brazed to the strands with a system that minimizes the
risk of initial leaks, and no leaks developing over the life of the winding.
f) On some higher voltage and larger units, a grading material is applied to the outer surface of the
bare bar. This material shall bond well to the bar, and be void-free.
Generator design voltages are attained by the designer through the variation of the following physical
factors: the number of coils in series, the length of the core, the coil pitch, the unit speed, and the number of
turns in the coil. Multiple-turn coils are used to multiply the voltage produced by the other parameters and
reduce the current per conductor. Conversely a multi-turn coil can be changed to a single turn coil,
providing that the number of parallels is equal to, or a multiple of, the number of turns subject to
Roebelling limitations. (There are other winding circuit/turn/slot configurations that allow conversion of
multi-turn windings to bar windings, as well.) These coils can be full coils or bars depending upon the
application and/or size of the generator. Both have the basic turn constructed from multiple strands of
insulated wire to form the conductor. The strands can be equal or non-equal in width and thickness. Equal
strand widths and thicknesses are the preferred choice when internal Roebel transpositions are used. For
coils without internal transpositions or with an inverted turn type transposition, unequal strand widths and
thicknesses can be arranged to form a brick-like construction, to hold shape during the conductor taping
operation and give a more stable conductor stack.
Full coils are used exclusively on most salient-pole generators and the smaller turbo-generators. They differ
from the bar construction by having a continuous conductor throughout, from the beginning to the end of
the coil. They are wound in a loop form from reels of wire, and then put in a coil spreader, to a form and
shape of the complete coil. Sometimes, additional forms are used to refine the shape. It is recognized within
the industry that the most prevalent failure mode of the multi-turn coil is that of turn-to-turn shorts. Most
phase-to-ground or phase-to-phase shorts in multi-turn coils are initiated by a turn-to-turn short. This
should place emphasis on the type and quality of turn insulation. High quality strand insulation may have
the turn-to-turn voltage withstand capability even under surge conditions but may not provide long-lasting
turn insulation over years of mechanical and electrical stresses. For this reason, many Owners will specify a
dedicated mica tape turn insulation for each group of strands that make up a turn within a coil. Such
dedicated taped turn insulation is of the same material used in the ground wall insulation, but is of less
thickness than the ground wall. Because of flexibility constraints associated with coil construction, different
installation techniques are required to install this type of winding.
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IEEE Std 1665-2009
5.4 Winding groundwall insulation

The groundwall insulation is the main high voltage electrical insulation that separates the copper
conductors from the grounded stator core in generator stator windings. The groundwall insulation is
designed for a steady state phase-to-ground voltage that establishes the volts-per-mil stress on the
insulation. In the event of a ground fault (phase-to-ground), the temporary overvoltage will increase by a
factor of √3 (the phase-to-phase voltage) as the neutral is isolated or connected to the ground by a very high
impedance. This also reduces homopolar currents to very low values. The opposite will appear in the case
of low impedances between the neutral and the ground. Low voltage circuit breakers and associated cables
between the generators and the step up transformer can create transient overvoltages. Fortunately, generator
ground wall insulation has very high impulse insulation strength ratings; but this is not true for turn-to-turn
insulation. Thus on multi-turn type windings, surge capacitors and arrestors are usually required.
In the rewind process, care should be taken that an adequate safety margin is included for kV/mm (or volts-
per-mil), to account for the potential of the phase-to-phase voltage as well as moderate transient
overvoltages. The thickness of the dedicated taped turn insulation in a multi-turn coil can be added to the
ground wall insulation thickness when calculating the operating volts-per-turn of a coil.
Surge capacitors and arrestors are sometimes used to protect the line end turn-to-turn insulation from
incoming surges. Surge capacitors were originally installed on many generators, but, in the early 1980s,
many of the generator manufacturers recommended removal of capacitors on all units that were single turn
coils, and directly connected to the electrical system. Therefore, many generators today may not be
equipped with surge capacitors. If the generator is equipped with the old style silicon carbide arrestors, they
should be replaced with metal oxide arrestors.
The groundwall insulation of stator windings is usually comprised of mica, glass, or organic reinforcing
material, and a bonding/impregnating resin. Windings manufactured today will typically be manufactured
using thermosetting epoxy resins.
Some smaller windings are made today with thermoplastic polyester resins. Generally speaking, polyester
resins are relatively inexpensive and characterized by good electrical properties and good resistance to heat
and mechanical impact. However, some polyester resins are sensitive to chemical reaction with moisture
that can cause both electrical and mechanical degradation. While windings manufactured with polyester
resins have given good operating service at moderate design demands, other more sophisticated
thermosetting epoxy resins are often selected, because of improved physical properties. The Owner is
advised to explore the service performance records accumulated with the less expensive polyester system
before using this insulation.
Groundwall insulation may be applied to the coil/bar using either of two common insulation systems: a) a
“resin-rich” tape , or b) a tape that starts with only a minimal amount of resin. With the resin-rich system,
all the impregnating resin is applied on the coil/bar before it is processed. The process is either a vacuum-
pressure autoclave cycle, or a hot pressing process. With the second insulation system, most of the
impregnating resin is applied to coil/bar after it enters a vacuum-pressure autoclave. Both systems have
performed well in service.
Some generator manufacturers are using a global vacuum pressure impregnation (VPI) process in the
factory for ratings up to at least 400 MW. For this method, low resin content tapes are applied to the
coils/bars, which are then installed in the stator; the endwindings are braced; the slot wedges installed and
windings connected; and then the entire stator core and winding assembly is subjected to the global VPI
process in a large tank. Generator windings of this type are much more difficult to repair and the global
VPI process cannot be repeated in the field. But regardless of the manufacturing method used, an
appropriate stator winding design, high quality materials, and careful control of the manufacturing process
are essential for a satisfactory winding. Regardless of the groundwall system, all Vendors generally use slot
surface grounding tape/paint, and an end-arm grading system. Especially for Roebel-bar windings, some
Venders could propose a winding design where the complete winding overhang is treated with grading
11
IEEE Std 1665-2009
material. In this particular case, the grading material has electrical contact with the bare copper at the ends
of the bars. The Owner should be aware that with this type of stress grading system, the measurement of the
winding insulation resistance and the polarization index test will have limited usefulness for the winding
condition assessment during routine inspections. The Owner should determine in the technical specification
whether complete stator winding overhang treated with grading material is acceptable or not.
Important considerations in application of the groundwall insulation include the following:
a) The bare coil/bar should be clean and of correct overall geometry, regarding shape and size.
b) All groundwall materials should be of proven performance.
c) Groundwall tape application should be in accordance with design specification.
d) Coil processing performance on each coil/bar should be verified to comply with process
specifications. (Application of temperature and pressure should be optimized.) It may be desirable
to monitor the insulation capacitance to verify that proper curing has occurred.
e) Finished coil/bar surfaces should be clean and free of contaminants.
f) Slot-grounding paint or tape and end-arm-grading paint or tape should be applied to correct areas,
stable mechanically, and of correct resistances.
g) On liquid-cooled windings, the strand liquid header should be free of contamination.
h) There should be satisfactory completion of all proof tests: overpotential, power factor, partial
discharge, strand and turn testing.
5.5 Generator end winding and connection rings support

The design of the endwinding support and connection rings will vary considerably between ratings and
speeds of the generator, and between manufacturers. Large generators, typically over about 200 MW, will
require elaborate support systems that will contain the very high forces associated with possible short
circuits. But of equal importance are the high vibrational forces and thermal expansion associated with
normal-load operation. The support systems on smaller generators may operate satisfactorily with designs
that rely on cord-tie support systems. Generally, ties that are made from a cured resin have been found
necessary on all but the smallest, low-duty machines. However, some Vendors do not use any ties in their
standard design. If the Owner wants ties, they should be written in the technical specification. Because
there are many systems variations that have been found reasonably satisfactory, it is difficult to define
details of endwinding specifications in this document.
Note that it is possible to rewind some generator stators while reusing the existing endwinding bracing
system for “basket” support systems. This introduces the issue of reusing the phase rings. Note that this is
an important decision point, because handling baskets and phase rings is labor intensive and can add
several days to the schedule.
Important considerations in the slot and endwinding support systems include the following:
a) The system should be of a laboratory test and/or service-proven design.

b) If re-using the old bracing system materials will be considered, it should be determined whether the
old materials meet the new design requirements.
c) If the system is fully cured and bonded, allowance should be made for thermal expansion of the
coils/bars in the slot, when energized.
d) All non-cured ties should be tight.
e) Coils/bars should be seated in supports and in the bottom of the slot, at end of slot.
12
IEEE Std 1665-2009
f) There should be no voids between blocks and the bars.

g) On vertical windings, there should be provision for restraining downward movement of the winding
and wedge system components.
Vibration forces in the end winding of a large turbine generator under normal load may be quite high, and
should be kept under control so that there is no wear incurred on the end-winding as a consequence of
rubbing or impacting. Thermal cycling and shrinkage effects can also promote advanced loosening and
high vibration. After the machine is installed and operating, limiting the maximum vibration level of the
endwindings and associated support structures to less than 50 micrometers peak to peak should be
achievable. This is unfiltered with no natural resonances in the frequency ranges of 50 Hz to 75 Hz, and
100 Hz to 140 Hz, for a 60 Hz system (40 Hz to 65 Hz and 80 Hz to 120 Hz for a 50 Hz system).
For turbine generators, a “bump” or “shaker” test should be specified so that the new stator winding will
return to service with minimal vibration and outside the above mentioned ranges. When doing these tests,
proper conditions should be applied. It should be ensured that all winding and support system blocking and
ties are fully settled and their resin binders cured. As well, for water cooled windings, the testing should be
carried out with the winding filled with water as this will add mass and drop the measured frequency as
much as 3 Hz. This more closely matches the operating condition of the winding. Bump or shaker tests
have limited applicability to stators with large numbers of poles, as there are a large number of localized
response modes and frequencies. On-load vibration testing is preferred if needed.
5.6 Slot support systems

Numerous types of slot wedging (support) systems have been used on generators. On smaller generators, a
flat wedge with slot fillers to apply downward pressure has been found satisfactory, if properly assembled.
On larger units, currently most manufacturers of turbo-generators use proven systems based on a radial
spring, compressed (as prescribed by the supplier) with either flat wedges or some variation of a “piggy
back” tapered double-wedge system. This spring will prevent rebound of a coil/bar off the bottom of the
slot, and minimizes the possibility of vibration, if the coil/bar is bottomed in the slot. Some manufacturers
augment the radial wedging with a side pressure spring. Some manufacturers include arrangements for
measuring the amount of ripple remaining in the radial spring. All of these systems can adequately support
the coils/bars in the slot, if they are properly installed and oil is not allowed into the machine. Oil
contamination in a turbo-generator will result in reduction of the coefficient of friction between the ground
wall and side ripple springs. As a result, coil movement occurs, as well as abrasion of the groundwall
insulation. Liquid cooled coils should be supported by conformable layers at the bottom of the slot to
dampen and prevent internal strand cracking. Regardless of the type of slot support system, the windings
shall also be carefully fitted to the stator slot in order to provide proper contact for the slot grounding paint
or tape, to prevent vibration and to conduct heat. Inadequate fitting in the slot may lead to significant slot
discharge activity.
Important considerations in winding slot support systems include the following:
a) All wedges should be tight, as confirmed and documented by measurement and test.
b) All wedges should be aligned to ventilation ducts as required.
c) Correct wedge materials should be used, per design requirements.
d) There should be no damage done to the core laminations.
5.7 Series/phase electrical connections and insulation

Adequacy of the electrical connections is vital to successful operation of the generator. Several methods of
making this connection at the series and phase leads are used. Usually, the electrical connection is made by
13
IEEE Std 1665-2009
brazing or soldering. The brazing process typically uses a silver alloy, and is performed at a higher
temperature than solder, which results in a much stronger bond. However, bolted connections are also used
on some designs by some manufacturers. On liquid-cooled generators, this connection may also incorporate
the liquid cooling circuit.
All responsible manufacturers will have designs that can be reliable if the workmanship is adequate. Some
important considerations include the following:
a) Use of a proven design with capable workmanship.

b) On brazed connections, all components should be clean before brazing. (Water-soaked material
used to protect the insulation during brazing can wick into the insulation system and cause failures
later in the winding life cycle, and thus should be avoided or used with caution.) The use of chill
blocks is preferred.
c) On bolted designs, dimensions should be absolutely correct, all fits should be proper, all hardware
should be locked, and all bolts should meet design requirement.
d) Electrical resistance of the winding copper should meet the specification at completion of winding
installation.
Three basic approaches are used in insulating the electrical connections: taped, potted, and electrical
clearance (spacing). Some designs will use potting at the series connections, and tape at the phase
connections. Similarly, where clearance is used for the isolation of voltage, the clearance may be made
greater at the phase locations. Overlap of the potting with the insulation is a critical dimension and should
be given serious thought. In all cases, only a service-proven design should be accepted by specification.
When spacing in an air atmosphere supplies a significant portion of the dielectric strength, it is extremely
important to consider the atmospheric altitude where the generator is operating.
On large units, it is a good practice to bring the end of the phase and neutral connection of each parallel
circuit out to the main bus or at the neutral bar. If the electrical clearance is sufficient, the designer may
choose to not insulate the connections.
6. Generator rotor considerations
6.1 Cylindrical rotors

Clause 6 is divided into two main subclauses. Sublause 6.1 addresses cylindrical rotors, and sublause 6.2
addresses salient-pole rotors. Annex E contains a more detailed discussion on the construction and
materials found in a cylindrical generator rotor. This discussion is included in this guide for information
only and is not an official part of the standard.
6.1.1 Rotor forging
In general the existing forging will be reused during a rotor rewind. Otherwise, basically a new rotor is
ordered. The new rotor may be a duplicate, or an upgrade/uprate. If a new forging is required, the forging
should be of the highest quality and vacuum degassed, because rotors are designed to operate at high
mechanical duty.
During a rewind, the forging should be given thorough NDE since cracks may be developing in the forging.
In addition, forgings made prior to 1960 were generally not made with vacuum de-gassed ingots and
therefore are subject to internal voids or occlusions. Typically, if there are cracks, they will be found under
14
IEEE Std 1665-2009
the retaining ring shrink-fit area of the rotor forging, at the top of rotor teeth, at the bore surface, or at the
rotor body axial centerline.
6.1.2 Rotor winding
There are three basic options for a rotor rewind: 1) re-insulate with the original conductors (usually
copper), 2) rewind in kind but with new conductors, and 3) install a new winding design, with possible
increased capacity. Each is briefly considered here:
a) Reinsulating with original conductors is typically the lower-cost route, although there may be
considerable cost involved in cleaning, straightening, and perhaps re-annealing the conductor. Also,
distortion and cracks may be found and shall be corrected.
b) Rewind with new conductors may be the quicker route, if new conductor material is ordered in
advance. Furthermore, this minimizes the risk that fatigue life of the conductor has been consumed.
It should be kept in mind that mechanical duty on some areas of the conductors can be high,
particularly on high-speed (2-pole) rotors.
c) A new winding design may be a preferred route if rotor winding reliability problems have been
experienced and/or an uprate in output may be desirable.
Regardless of the option taken, the conductors should be of correct shape, hardness, and surface conditions
(to allow for friction coefficients).
There are some rotors that have conductors made from materials other than copper. Aluminum alloys, such
as “Condol,” were used in the 1950s instead of copper. These special alloys may not be readily available
today for repairs to the conductors. Also, it may be difficult to redesign a rotor using copper conductors,
instead of an aluminum alloy, because copper—which is heavier—may produce additional angular and
radial forces.
6.1.3 Rotor winding turn insulation
Three general approaches are taken to insulating the copper turns: 1) all taped turns, 2) insulating separator
strips in the slots, and 3) insulating strips throughout the winding. Continuous taping offers more protection
from contamination, but is relatively uncommon. When used, alternate turns may be taped in order to
reduce the amount of insulation buildup.
The more common approach is to use only insulating strips. It is essential that the strips be permanently
bonded so that they do not migrate out of position, and the insulation commonly is bonded only to one side
of each turn.
6.1.4 Rotor winding slot insulation
Two approaches are used for insulating the copper from ground: 1) a total enclosure of the coil copper by
applying insulation overall (for indirect cooling), and 2) slot cells (for direct cooling). The “indirect
cooling” is commonly used only on smaller rotors because the insulation does not permit removal of heat
from the conductor. The “direct cooling” approach is more vulnerable to contamination than the “indirect
cooling” approach, because clean, dry creepage paths are used throughout the winding to support the rotor
voltage. However, because cooling gas is in direct contact with the copper winding, a much higher capacity
can be obtained from the rotor. As a result, “direct cooling” is common on all but smaller rotors.
It is common that cooling gas is discharged radially through holes in the wedge and top-of-slot creepage
block. In these designs, care should be taken to verify that when installing the winding, all holes are in
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IEEE Std 1665-2009
correct alignment, and that the design of the insulation system will not permit axial movements that lose
this alignment of the holes.
It is important that the underside of the top-of-slot insulation that contacts the copper turns have the correct
surface friction coefficient, to allow for thermal expansion and contraction of the winding.
6.1.5 Slot wedges
Slot wedges operate at very high mechanical stress. Generally wedges are made of steel, although
aluminum is sometimes used, as well as other alloys. In some rotor designs, magnetic wedges are used in
the slots next to the poles for flux shaping. Because mechanical duty is high the wedges should receive a
full NDE for cracks and other deficiencies. It is not uncommon during disassembly of the rotor coil slots to
find electrical arc damage on the wedges, due to negative sequence currents. It is very important that any
arc damage be blended out since it would act as a stress riser for future crack initiation. In some cases, the
arc damage is so severe that a large number of the wedges have to be replaced.
It is essential that wedge patterns be symmetrical axially and circumferentially. Where a flux probe is
installed in the stator to detect shorted turns in the rotor, all wedges in the probe’s axial position have to be
non-magnetic, otherwise the sensitivity of the probe to shorted turns is lost.
6.1.6 Endwinding blocking and insulation
Design and assembly of endwinding blocking is a critical issue on high-speed (2-pole) rotors. The block fit
shall be symmetrical circumferentially to assure that all coils are restrained equally. Also, axial fit shall be
sufficiently close, in order to hold the coils in proper position and prevent turn distortion. Deviation from
the original manufacturer’s basic design approach to blocking is sometimes necessary, because when
changing from a retaining ring with ventilation holes, a different ventilation system has to be used. Also in
the case of distorted turns, a design change may be required to correct the inherent problem.
CAUTION
Use caution when reusing any blocking material manufactured prior to 1988, because it may contain
asbestos.
In those designs where axial position of the top-of-slot creepage block is held by the retaining ring
insulation, assembly tolerances for the blocking shall be held precisely.
The retaining ring insulation shall be of correct thickness and surface dimensions. In addition, the surface
shall contain a slip layer to minimize the friction coefficient between the retaining ring insulation and the
copper coils. In some of the spindle mounted retaining ring designs, the original design did not allow
sufficient freedom of movement between the coil and the insulation, resulting in uneven growth of the coil
and subsequent vibration. As a remedy, the addition of a fluoropolymer resin slip layer (such as DuPont™ 8
Teflon® 9,10 ) can provide the necessary freedom of movement.
8
DuPont™ is a trademark of E. I. du Pont de Nemours and Company.
9
Teflon® is a registered trademark of E.I. du Pont de Nemours and Company or its affiliates.
10
This information is given for the convenience of users of this standard and does not constitute an endorsement by the IEEE of these
products. Equivalent products may be used if they can be shown to lead to the same results.
16
IEEE Std 1665-2009
6.1.7 Retaining rings
The most highly-stressed component in the generator is the retaining ring. (This is sometimes referred to as
a “rotor end cap”.) Its purpose is to restrain the angular and radial acceleration forces of the rotor winding
end-turns. Its strength determines rotor diameter limits. Non-magnetic steel retaining rings have been in
general use in almost all large generators since the 1950s. The non-magnetic alloy used by most
manufacturers between the 1950s and 1980s is subject to stress corrosion cracking. Replacing the retaining
rings with a new alloy ring will significantly reduce the risk of a severe failure and unscheduled outages.
Annex E has a thorough description of retaining rings, and their inherent risks.
6.1.8 Collector rings and bore copper
The insulation systems for the collector rings, terminal studs, and bore copper are not subject to the same
wear as the coils’ insulation systems, and typically last much longer. For this reason, they typically are not
automatically included as part of a rotor rewind. But, they should be evaluated for unexpected wear, and
good surface film condition (also known as patina). Uneven wear on the collector rings can be corrected by
machining on the rotor. If the wear is too great, they can be replaced. If the rings are machined, or replaced,
a proper film shall be established, after the generator is returned to service. A proper film is a result of a
combination of adequate moisture in the air, carbon from the brushes, and adequate current density on the
face of the brushes. The radial lead seals should also be tested and replaced, if necessary, on hydrogen-
cooled generators.
In large machines, a helical groove is made in the collector ring to reduce the operating temperature. This
groove may have a small radius at the bottom to avoid sharp edges.
6.1.9 Miscellaneous rotor components
The entire rotor should be evaluated if taken apart for a rewind. It may be desirable to upgrade pole cross-
over straps to a flexible design, or to replace old end turn blocking material with a new glass type blocking
material.
6.2 Salient-pole rotors
6.2.1 Rotor categories
Salient-pole machines fall under three principal rotor categories: integral-pole rotor, shaft rotor, and shaft-
and-spider. Annex F has a thorough description of salient-pole rotors, and their inherent risks.
6.2.1.1 Integral-pole rotors
Integral-pole rotors are found in high-speed (4-pole and 6-pole) units. In this construction, the poles, pole
tips, and shaft are usually machined from a single forging to produce superior mechanical properties.
Integral poles do not have laminations, and they usually do not employ circuit elements such as shorting
segments or amortisseur bars (also known as damper windings). Some integral-pole rotors have separate
pole tips that are bolted into the pole body. Pole faces on integral-pole rotors are usually machined in such
a way to simulate a lamination stacking, in order to reduce the pole face losses.
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IEEE Std 1665-2009
6.2.1.2 Shaft rotors
Shaft rotor constructions are also used in high-speed units or units where very high inward-directed radial
acceleration-type forces act on the poles. The poles are comprised of laminations stacked in the axial
direction of the rotor, and held together under compression by endplates and rivets. These dovetail designs
use sets of long tapered keys driven between the side of the pole dovetail and matching dovetail of the rotor
rim. These keys usually extend the length of the pole. The body of the rotor (or shaft) is typically made
from a machine forging or constructed from steel plates or laminations. The poles can be attached to the
rotor by means of dovetails, T-shaped keys, or bolts. Bolted poles should be removable from inside the
rotor rim, to allow the possibility of removing one pole without removing the rotor.
6.2.1.3 Shaft-and-spider rotors
Shaft-and-spider rotors are typically found in low-speed generators. They have a straight shaft to which a
disc-shaped steel plate (the spider) is keyed, bolted, or shrunk-fit. In some hydrogenerators, the spider and
the rim can be made of cast steel. In large hydrogenerators, the spider has radial arms against which a
laminated rim is piled to form a solid cylinder type component. The diameter of the spider is much larger
than that of the straight shaft that carries it. The individual laminated wound poles are in turn bolted, or
keyed with dovetails or T-shaped keys to the outer diameter of the rim. A fabricated hub with shaft
extensions is also possible. These poles are often equipped with amortisseur (damper) bars and shorting
segments.
6.2.2 Shaft, spider, and rim
These items are not a subject of this document, but it is prudent to conduct a rigid inspection of these items
during any salient-pole rotor rewind. An engineering analysis should be performed on these components if
an uprate is being considered.
6.2.3 Poles and damper windings
On some rotor designs, the damper winding and pole pieces have to be removed in order to gain access to
the old rotor winding The poles are usually detached from the rotor by extracting the bolting or the dovetail
keys. Some European high speed (4-pole and 6-pole) designs have bolt-on-pole tips that have to be
removed to access the field pole windings for repair. On high speed generators, “V” blocks (pole braces)
between the poles have to be dismantled prior to pole removal. (The function of these blocks is to support
the rotor coils against the radial acceleration related centripetal forces.) Some of these blocks are made of
metal with separate insulation components, while others are made from solid blocks of insulation material.
Lifting and handling of the poles should be arranged in advance, prior to detaching the poles. After the old
rotor coil windings are removed from the poles, the poles should be cleaned by glass bead blasting, and the
damper winding should be tested for cracks.
6.2.4 Rotor coils
On salient-pole rotors, there are two types of rotor coils. There are: 1) wire wound coils (those made from
rectangular insulated wire); and 2) strap wound coils (those made with large rectangular strap, which was
edge bent or brazed into the coil form). Strap wound coils need turn-to-turn insulation inserted between the
turns prior to the consolidation of the coils. Old coils typically used asbestos for this turn insulation.
Modern strap wound coil designs use a synthetic aromatic polyamide insulation (such as Nomex® 11 , 12 ),
11
Nomex® is a registered trademark of E.I. du Pont de Nemours and Company or its affiliates.
12
18
IEEE Std 1665-2009
which has the thermal, mechanical, and electrical properties that are adequate for this application. Some
strap wound coil designs contain extended turns to improve the cooling. This configuration shall be
maintained. Since there are huge rotational mechanical forces acting on the coils, it is essential that they are
well-bonded into a monolithic structure. The groundwall material consists of insulation applied to the tops
and inside surfaces of the coils. The outside surfaces are bare, to provide cooling. Top and bottom
insulating washers (or collars) are supplied to give additional creepage insulation surfaces to ground.
On some generators, the rotor coils are designed to carry the current in one direction on one pole, and in the
other direction on the next pole. These are called open or crossed coils. On other generators, all the rotor
coils are wound in the same direction and special connections are installed on top of the rotor rim to carry
the current in one direction in one pole and in the other direction in the next pole.
The rewind materials should include the following: connecting material, top and bottom washers,
tightening materials, pole brace insulation, and tapered keys if applicable. If the design contains springs,
these should be re-qualified or replaced.
6.2.5 Collector rings
During a rewind of a salient-pole rotor, it is important to inspect and address any issues with the collector
ring insulation and the connecting straps or cables. Replacement or reinsulation may be necessary. The
brush rigging should also be inspected, cleaned, and re-treated. Related equipment should also be evaluated
during a salient-pole rotor rewind. For example, it may be desirable to replace variable-pressure brush
holders with constant-pressure brush holders.
In large machines, a helical groove is made in the collector ring to reduce the operating temperature. This
groove needs to have a small radius at the bottom to avoid sharp edges.
7. Writing the technical specification
7.1 General
A technical specification can take on many forms, from simple to complex. A good specification, however,
is one that has sufficient detail to enable the desired level of quality to be achieved, but not so extensive
that it encumbers the Vendor’s design effort. The Vendors generally have a specific design standard, which
usually provides the necessary level of quality and reliability that an Owner will want. However, during the
production of the components and the assembly, many things can go wrong. The technical specification is
used to clarify the design requirement aspects of the equipment and the steps necessary during
manufacture, to check and ensure that quality is built in throughout the manufacturing process, and can be
referred to for acceptance criteria upon completion. Another important aspect is to be sure the calculations
(mechanical, thermal, etc.) are well-performed before the proposal of a certain design by the Vendor, and
respond correctly to the specifications. The following annexes offer a description of the common
components found in a typical specification.
⎯ Annex G contains two useful tables of information that are typically supplied by the Owner, or by
the Vendor.
⎯ Annex H contains an extensive list of questions, which should be helpful in formulating the actual
scope of the project.
⎯ Annex I is a typical specification for the stator rewind of a turbo-generator.
⎯ Annex J is a typical specification for the rotor rewind of a turbo-generator.
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IEEE Std 1665-2009
⎯ Annex K is a typical specification for the stator rewind of a hydrogenerator.

⎯ Annex L is a typical specification for the rotor rewind of a salient-pole hydrogenerator.
The tables and the sample specifications in the annexes are included for illustration only and are not an
official part of the guide.
7.2 Objective
A typical specification begins with an objective, which is a clear statement of the Owner’s intent. Does the
Owner want a rewind in kind, or does the Owner want improvements? The plans for future operation
should be clearly stated here.
7.3 Project description

The project description is a written document that should give the potential Vendor a verbal picture of the
project, along with a description and location of the plant site. The expected outage schedule should be
defined and any other planned work identified, so that rules of shared equipment (such as cranes) are
clearly understood. The generator’s nameplate information is provided, along with a brief history of its
maintenance and operation. Any manufacturer’s bulletins or advisements should be identified, along with
their status (whether or not they have been adopted). The unit history should particularly include
commissioning and performance test results where available. An opportunity to read operational data such
as temperatures and loads should be considered to minimize performance prediction risks. If there is an
opportunity to pre-measure the generator, the contact personnel and time period can be provided here. The
bid contact personnel and the bid return dates should be included also in the project description.
7.4 Definitions
A section on definitions is important to identify the terms that are used in the specification. Reference to
industry standards can be included here, but care should be used so that they do not conflict with other
requirements set forth in the specification. For example, if the Owner references IEEE Std C50.13, and then
adds certain design requirements, thermal limits, or monitoring necessities, there then needs to be a clear
statement showing an exception has been taken to the referenced standard.
7.5 Scope
In the scope, it is necessary for the Owner to clearly define the work scope as well as the technical
requirements. The Owner should decide on how much design detail, if any, is to be contained in the
specification. One option is to prepare a purely functional specification (or performance specification). In
this case the writer focuses on the machine output and the operating conditions. Another approach is to
specify certain design features, or processing methods. The danger in this approach is that it may place
unnecessary responsibility on the Owner, and might preclude design features that would be better for the
application. Unless the Owner has generator design experience, it may advisable to have the prospective
Bidders specify the details of their design, and materials. However, even the performance specification
should identify any known design weakness, and a request for the Vendor’s design solution.
The Owner should require enough detail in the Bidder’s proposal so that it is clearly understood by both
parties what is and is not included in the bid. For example, core and frame cleaning is something that has to
be done on almost every rewind. The frame cleaning may necessitate the removal of stator hydrogen or air
coolers. But the extent of required cleaning will vary by generator. The scope of work can require the
Bidder to include the estimated hours for core cleaning in their base price, and an hourly rate for any
20
IEEE Std 1665-2009
extraordinary work. The scope can also require the Bidder to include an evaluation for core tightness, and
an hourly rate for tightening the core, if necessary.
The scope should require that the Vendor have a good quality program and be required to present it in
detail. The program should include material tests and installation inspections performed to meet their
quality requirements. Some tests, such as the accelerated endurance tests, may be waived to save time and
money, if the Vendor can produce acceptable test records from similarly sized windings for an identical
insulation system.
The scope should require the Vendor to provide the Material Safety Data Sheets (MSDS) for all materials
used on site for a rewind. Any excess material brought in by the Vendor should be removed by the Vendor
at completion of the rewind.
The addition of monitoring devices should be included in the scope. Thermal sensors [such as resistance
temperature detectors (RTDs) and thermocouples (TCs)], and vibration sensors are not always part of the
standard material requirements. For example, on direct-cooled coils, IEEE Std C50.13 does not require the
manufacturer to install embedded temperature detectors (RTDs or TCs) in the stator slots. Instead, it only
stipulates temperature detectors at the coolant discharge. Therefore, if the Owner of a turbo-generator
wants temperature detectors embedded in the stator slot, they should be specified here in the scope.
7.6 Work conditions

This part of the specification should address issues such as site access, storage of materials, lay-down
space, local labor agreements, safety practices, environmental requirements, housekeeping, and facilities
(offices, lunchrooms, toilets etc.) Information on the site utilities should also be provided to the Bidders.
This includes the ampacity of local voltage service, lifting requirements, crane limitations, capacity of
house compressed air and house service water, and the connector types and sizes. In addition to the work
conditions just mentioned, any hazardous materials should be identified, and methods of abatement and/or
personnel protection required should be identified. Quality standards for assessing site conditions (ISO or
others) should also be included here.
7.7 Foreign material exclusion

Foreign material exclusion (FME) is a set of procedures intended to minimize the possibility of intrusion
into the machine of foreign material before, during, and after the inspection. In principle, the definition of
foreign material is anything not normally present during the operation of the generator that may adversely
affect its constituent components if left there. It is important not to inadvertently contaminate the generator
with such things as water, corrosive liquids, and personal items like pens, keys, flashlights, and other
metallic objects. Sometimes these materials can be introduced by walking on them and then walking into
the machine. Therefore, in situations where stringent FME rules are applied, paper or rubber booties are
worn over the shoes to minimize this risk as well as protect the surfaces walked on in the machine. A lack
of adequate access control can be the cause of serious damage to the stator or rotor of a large generator—in
particular, the stator winding. Thus, it is critical to account for all tools and parts coming in and out of a
generator during an outage.
A good FME program will include clearly-written procedures addressing all aspects of training and
implementation. Responsibilities should be clearly defined, as well as contingencies for the loss of FME
control. A typical FME procedure may include FME signs, FME zones, appropriate clothing, tool control,
and spare parts controls.
21
IEEE Std 1665-2009
7.8 Deliverables
This part specifies what is expected of the Bidder in their answers to the bid request. It may include
requests for schedules, their quality program, the specifics of their design, the various breakouts of the
pricing, specific answers to questions asked throughout the specification, and their experience list
7.9 Commercial issues

Included in this section are the terms and conditions required by the Owner including their specific terms of
payment.
7.10 Attachments
Included in this section can be the plant rules and safety guide, any drawings available, and the specific
pricing sheet.
8. Testing
8.1 General
Acceptance testing is necessary for a generator stator or rotor rewind. This guide will not discuss all the
details of these tests; or the pros and cons of each test. Where existing test standards are available they
should be used. This guide will offer some recommendations on test values not already covered in existing
standards. There are many variables and differences based on specific situations, conditions, and
manufacturing techniques. All testing, type of test, test method, voltage level, duration, and acceptance
criteria should be discussed and agreed upon between the Owner and Vendor before a rewind contract is
signed. If an industry standard is not applicable, a detailed discussion should take place and a test protocol
put in writing and approved.
Recommended tests are divided into three categories: manufacturing tests, progressive testing during
assembly (rewinding), and final acceptance tests.
Testing standards referenced here are listed in Annex A. Other significant standards for synchronous
generators are: IEEE Std 67, IEEE Std 115, IEEE Std 393, and IEEE Std 1043.
8.2 Stator core

Often the core does not need significant repair work during a stator rewind. However the core iron can be
damaged during the rewind process. Core testing is a way to determine if damage did or did not occur. A
low flux or high flux (loop test) should be considered for all stator rewinds. Testing should be done in the
following three steps:
a) Before removing the wedges and coils/bars—this will establish a base line
b) After removing all wedges, coils/bars, and cleaning the core slots
c) After installing all coils/bars and wedges—to confirm core integrity
If the core is in good condition and the low flux test shows no indications, a loop test may not be necessary.
But, if there is any doubt about the integrity of the core, a loop test should be performed. Some Owners
22
IEEE Std 1665-2009
report that a low flux test does not always detect core problems, especially on cores that have splits. A low
flux test does not provide any core vibrations that are necessary to detect shorted laminations under
operating-like conditions. Loop test flux levels or durations should be lowered, if required, to avoid core
temperatures in excess of 20 °C over the frame temperature in order to prevent buckling due to compressive
stresses. All core clamping bolts should be checked for rated torque before and after each loop test. Some
precautions are required to ensure that no extra torque will be applied to core studs. In some hydrogenerator
designs, the clamping bolts are welded to a stator frame flange at a location about midway axially in the
frame. It could be a good practice to check for rated torque at the bottom of the core as well as at the top.
Static torque is higher than dynamic torque. To avoid extra torque it is better to slightly unscrew, and then
torque the bolt at the original torque design, one by one. Before the core test, an inspection should be made
to remove any foreign metallic pieces close to the stator iron.
All core clamping bolt insulation should be checked with a 500 V insulation resistance tester by the
generator’s Owner before writing the rewind specification, because deteriorated bolt insulation may need to
be replaced during the rewind. Typically, core clamping bolt insulation that is older than 40 years should be
replaced during a rewind, because the insulation is only accessible during a rewind with all the coils
removed.
If there has been a history of core tightening during previous maintenance outages, consideration should be
given to whether or not the core bolts need to be replaced.
On hydrogenerators having core splits, a low flux test can be misleading. Further, low flux core tests do not
induce rated core plate voltages nor create in-service vibration conditions.
When replacing cores and uprating a machine, the Vendor may change machine reactances and even rated
core flux levels. The Owner should be made aware of the possible changes, if any.
8.3 Stator winding

To manufacture a quality product, to detect potential damage to the product during the installation, and to
offer certain level of assurance for future operation, 8.3.1, 8.3.2, and 8.3.3 contain recommended tests and
test levels for stator windings. Design techniques and manufacturing processes vary throughout the
industry, and hence it is often difficult to cover all the issues with existing specifications. This is why a
discussion between the Owner and Vendor is recommended to achieve the agreement regarding the testing
requirements.
8.3.1 Coil manufacturing tests

Table 1 is a list of recommended manufacturing tests, followed by a list of optional tests.
23
IEEE Std 1665-2009
Table 1 —Recommended manufacturing tests
Winding type
Reference Test
Multi-turn coils Bars
Shape /dimensional checks 9 9
Strand continuity test 9 9
Strand-to-strand isolation test 9 9
End to end surface resistance
9 9
measurement
Power factor or dissipation

IEEE Std 286 9 9
factor tip up
IEEE Std 522 Turn insulation test 9

IEEE Std C50.12 or C50.13,
or IEEE Std 4, ac or dc high potential 9 9
or IEEE Std 95
The following tests can be performed, if so chosen, and agreed upon between the Owner and Vendor:
a) Partial discharge test on every coil or on a sample number of coils, per IEEE Std 1434 or ASTM
D1868
b) Lights-out corona test or corona-scope test (no industry standard exists for quantification, but the
test is valuable for detecting abnormalities in the winding. It is useful to spot grading paint damage
that may have occurred during installation. At this point repairs are easy to make and thereby keep
ozone generation down to a minimum.)
c) Voltage endurance test for prototype and/or production samples—reference IEEE Std 1043
d) Thermal cycling for prototype and/or production samples—reference IEEE Std 1310
During the negotiation process, the Vendor and Owner may wish to agree on a program of testing, using
some of the above tests at an independent lab on prototype and/or production coils.
8.3.2 Rewind assembly tests
Progressive testing is recommended during the rewind to identify marginal or weakened insulation, and to
provide a reasonable assurance that the winding will successfully pass the final test as per 8.3.3. This can
be achieved by applying the tests listed below, in Table 2. These tests are made to verify that the Vendor
will meet the final test required by the contract. A schedule of the Vendor’s tests should be requested for
bid evaluation.
The Owner should make it clear, in the rewind specification, that whenever a coil or bar fails the
overpotential test, the Vendor should either:
a) Strip, re-insulate, and re-use the coil or bar; or

b) Scrap the failed coil or bar
24
IEEE Std 1665-2009
8.3.3 Final acceptance tests
The final overpotential test is to be performed after the winding assembly is completed (connections,
wedging, bracing), and just before the final paint is applied. (Generally, a 5 kV polarization index test is
done before the overpotential test.) The winding shall not be high-voltage tested until the polarization index
test results are accepted by the Owner. Extreme variation between phases is cause for concern and possible
rejection. The final test level is twice the rated line voltage plus 1000 V, i.e., (2 × VL-L + 1) kV ac, for 60
seconds. Equivalent dc level is 1.7 × (2 × VL-L + 1) kV. It is recommended to test each phase separately
with the other two phases grounded. If the individual neutrals are not brought out of the machine, perform
this test before joining the neutrals. See IEEE Std C50.12 or IEEE Std C50.13 as applicable.
The final temperature detector test is usually 1500 V ac or 2500 V dc for one minute. Temperature detector
manufacturers should be consulted to determine the proper test levels.
The following tests can also be performed, if so chosen, and agreed upon between the Owner and Vendor:
a) Measurement of stator winding resistance—each phase individually—reference IEEE Std 115

b) Insulation resistance—reference IEEE Std 43
c) Polarization index—reference IEEE Std 43
d) Slot discharge (corona probe) test—reference IEEE Std 1434
e) Lights-out corona test or corona scope test (no industry standard exists for quantification)
f) End-turn frequency response test (bump test)—recommended for turbo-machines with water-
cooled windings
g) Timed step or ramped dc voltage test—reference IEEE Std 62.2 and IEEE Std 95
h) Cooling media flow tests
25
IEEE Std 1665-2009
Table 2 —An example of stator winding installation progressive tests
Test Multi-turn coils Bar

Coolant flow N/A On direct-cooled bars
Overpotential During placement of the pre-lift coils, apply a one minute N/A
-coil groups ground test equal to 125% of the value of the final test (see
8.3.3), to each convenient group of coils as the work
progresses. On those coils whose slot sections are not
entered into slots, apply a temporary ground on the
semiconductive surface.
Surface For coils/bars with a semi-conducting slot finish, the resistance between coil/bar surface and ground
resistance should be measured at three places on each leg as the coils/bars are installed, and before the wedges
are installed. If high resistance readings are obtained, the coil/bar sides involved should be checked
for coil tightness. If coils/bars are tight and readings are still high after repacking, the coil/bar
surfaces involved should be probed with an ohmmeter to determine if certain areas have insufficient
conducting varnish coverage.
Overpotential For coils/bars, after side packing in the slots, apply a one-minute ground test equal to 125% of the
(temporary value of the final test (see 8.3.3) to each convenient group of coils/bars as the work progresses.
overvoltage)
Overpotential For coils/bars, after wedging of the coils/bars in the slots, apply a 1-minute ground test equal to
(temporary 120% of the value of the final test (see 8.3.3) to each convenient group as the work progresses.
overvoltage)
Temperature Temperature detectors (RTDs or TCs) are to be tested for correct detector function between leads
detector test prior to insertion, and with overpotential, for one minute, after slots containing a detector are fully
wedged. Detector manufacturers are to be consulted to determine recommended test levels.
Turn The turn insulation test (IEEE Std 522) should also be performed as a progress test on the coils, at a
insulation test peak voltage and rise time agreed upon between the Owner and Vendor.
8.4 Rotor winding
8.4.1 Rewind assembly tests
Attention should be paid to the assembly of the rotor winding, slot liners, and blocking. As with the stator
winding, a discussion with the Vendor is important to agree upon the tests to be completed. Tests might
include the following:
a) Turn-to-turn test on each pole

b) Insulation resistance
c) Pole drop test
d) Coil surge test
e) Winding resistance test on each pole
8.4.2 Final acceptance tests
The following tests can be performed, if agreed upon by the Owner and Vendor.
a) Insulation resistance
b) Polarization index
26
IEEE Std 1665-2009
c) Pole drop test on assembled rotor, at standstill, or a flux probe test in the balance pit
d) AC high potential—reference IEEE Std C50.12 or IEEE Std C50.13 as applicable
e) Impedance test
f) Pressure test of cavity (for hydrogen-cooled machines)
g) Winding resistance corrected to 75 °C
8.4.3 Rotor balance
For turbo-generators, there are differing opinions on the need to perform a full-speed balance after rotor
winding work. Some say that a full speed balance is not necessary on a cylindrical rotor, if the rotor
winding was re-insulated using the same conductor in the same slots. (If a portion of the insulating
materials are replaced, they shall weigh the same as the replaced material.) However, if the conductors are
replaced, (or there is a history of rotor balance problems/instability), a full-speed balance is necessary.
Some say that after winding re-insulation or replacement, a slow speed balance (300 rpm to 500 rpm) is of
no value on cylindrical rotors. Rotors requiring an overspeed test should be limited to 110% of full speed
when using old retaining rings; and 120% of full speed with new rings.
For a salient-pole rotor, some say that a full speed balance is not necessary if the rotor winding was re-
insulated using the same conductor on the same poles, provided each pole is reinstalled at the same location
on the rotor rim. A balance check and record is advisable, in any case.
8.5 Other tests

The following tests are not always performed after a stator or rotor rewind. However, they may provide
required regulatory information or useful information to the Owner.
a) Open-circuit saturation test (see Note 1)

b) Short-circuit saturation test (see Note 1)
c) Voltage balance test
d) Sudden short circuit test
e) Heat run test (see Note 2)
f) Segregated losses and efficiency test.
NOTE 1—An open-circuit saturation test and short-circuit saturation test can validate connections and integrity before
grid connection.
NOTE 2—Heat run tests may be appropriate on hydrogenerators because replacement windings with different
stranding and/or different end arm heights can and have affected the hydro unit efficiencies. A heat run test can also
verify that the new winding temperature does not exceed the generator’s cooling capacity.
27
IEEE Std 1665-2009
Annex A
(informative)
Bibliography
[B1] Bartnikas, R., Editor, Engineering Dielectrics: Electrical Properties of Solid Insulating Materials:
Measurement Techniques, Vol. II B. Philadelphia/West Conshohocken, PA: STP 926, ASTM, 1987.
[B2] Dakin, T.W. “Measurement of partial discharges in inductive apparatus: transformers and rotating
machines,” in Engineering Dielectrics, Vol. I, Corona Measurement and Interpretation, R. Bartnikas and
E.J. McMahon, Editors, STP 669, ASTM, Philadelphia / West Conshohocken, PA, 1979.
[B3] Eastment, E., and Smith, J. “Utilizing CO2 Methods to Clean Generator Components,” Proceedings
of the 2005 International Conference of Doble Clients.
[B4] Gonzalez, A.J., M.S. Baldwin, J. Stein, and N.E. Nilsson, Monitoring and Diagnosis of Turbine
Driven Generators. Englewood Cliffs, NJ: Prentice-Hall, 1995.
[B5] Gupta, B.K., Stone, G.C., and Stein, J. “Use of AC and DC Hipot Tests to Assess Condition of
Stator Winding Insulation,” Proceedings of IEEE Electrical Insulation Conference, Chicago, September
1995.
[B6] IEEE Std C37.101™, IEEE Guide for Generator Ground Protection. 13
[B7] IEEE Std 56™, IEEE Guide for Insulation Maintenance of Large Alternating-Current Rotating
Machinery (10 000 kVA and Larger).
[B8] IEEE Std 421.1™, IEEE Standard Definitions for Excitation Systems for Synchronous Machines.
[B9] IEEE Std 492™, IEEE Guide for Operation and Maintenance of Hydro-Generators.
[B10] IEEE Std 1147™, IEEE Guide for the Rehabilitation of Hydroelectric Power Plants.
[B11] IEEE P1719™ Draft 20, June 2009, Draft Guide for Evaluating Stator Cores of AC Synchronous
Electric Machines Rated 1 MVA and Higher. 14
[B12] ISO 3746, Acoustics – Determination of Sound Power Levels of Noise Sources – Survey Method. 15
[B13] Kerszenbaum, Isidor. Inspection of Large Synchronous Machines. Piscataway, NJ: IEEE Power
Engineering Society, IEEE Press, 1996.
[B14] Klempner, Geoff. “Specifying a Quality Rotor,” International Electric Machines and Drives
Conference, Cambridge MA, 2001.
[B15] Klempner, G., and I. Kerszenbaum, Operation and Maintenance of Large Turbo-Generators. New
York: John Wiley & Sons, Inc., 2008.
[B16] Serafin, Joel D. “Using Technical Specifications for Water Cooled Generator Stator Rewinds,”
Electric Machines and Drives Conference, Cambridge MA, 2001.
[B17] Spisak, Andrew. “Specifying a Machine,” International Electric Machines and Drives Conference,
Cambridge MA, 2001.
13
IEEE publications are available from the Institute of Electrical and Electronics Engineers, 445 Hoes Lane, P.O. Box 1331,
Piscataway, NJ 08854, USA (http://standards.ieee.org/).
14
This IEEE standards project was not approved by the IEEE-SA Standards Board at the time this publication went to press. For
information about obtaining a draft, contact the IEEE.
15
ISO publications are available from the ISO Central Secretariat, 1, ch. de la Voie-Creuse, Case postale 56 CH-1211 Geneva 20,
Switzerland (http://www.iso.org/) ISO publications are also available in the United States from the Sales Department, American
National Standards Institute, 25 West 43rd Street, 4th Floor, New York, NY 10036, USA (http://www.ansi.org/).
28
IEEE Std 1665-2009
[B18] Stone, G.C., E.A. Boulter, I. Culbert, and H. Dhiarni, Electrical Insulation for Rotating Machines.
Piscataway, NJ: IEEE Press, 2004.
[B19] Timperley, J. “Specifying Generator Testing,” International Electric Machines and Drives
Conference, Cambridge MA, 2001.
[B20] Ward, Robert. “Guide to Writing a Stator Rewind Specification,” International Electric Machines
and Drives Conference, Cambridge MA, 2001.
29
IEEE Std 1665-2009
Annex B
(informative)
Glossary of commonly used generator terms
A_
AC exciter – An ac machine that is rectified to provide dc current to the field.
Air gap – The space between the rotor and the stator core.
Amortisseur windings, damper windings – Conductors located on the rotor that provide a low resistance
path for undesirable rotor surface currents, and have an active role for the damping of high
disturbances generated by the network.
Armature – The main winding in a rotating machine, in which alternating voltage is generated by virtue of
relative motion with respect to a magnetic flux . In an ac machine, the armature is generally the
stationary winding and is synonymous with the stator. This term is also commonly used to denote
the rotating winding of a dc machine.
Asbestos – A natural occurring silicate material with long fibers. Asbestos is a known carcinogen. It was
widely used for a wide range of manufactured goods, including roofing shingles, floor tiles, and
electrical insulation. In 1979, the USA banned all new uses of asbestos; however use of equipment
containing asbestos established before this date are still permitted. Any abatement work, cleaning,
and disposal of asbestos materials shall be performed according to appropriate government
regulations.
Asphaltum insulation – A thermoplastic electrical insulating system for generators containing asphalt used
up until the mid–1960s.
Auxiliaries – Equipment external to the generator required for its satisfactory operation, including the
hydrogen gas system, bearing lubricating oil system, seal oil system, alarm system, and generator
component water cooling system.
Axial core ventilation – Cooling of stator core iron laminations by the passage of gas through axial holes
extending the length of the core.
B_
Back iron – The portion of a laminated generator stator core, in back of the winding slots; also known as
the yoke.
Baffle ring – See Zone ring and Rotating barrier.
Bar – The terms “bar” and “coil” are used in electric machinery, but are not interchangeable. A bar is
usually considered to be half of a coil, and is most often applied to single-turn coils.
Basket – Conic support device that serves as part of an end turn mechanical bracing system.
BCT (bushing current transformer) – An instrumentation device encircling a bushing that steps down the
current in that bushing, usually to a nominal value of 5 amperes.
Bearing Babbitt – Tin alloy used to line the bearing into which foreign particles ablate to prevent damage to
the adjacent shaft journals.
Bearing bracket – The device located on each end of the generator that supports each bearing and provides
a gas-tight seal for the stationary parts.
Blower – A fan-like device that circulates the cooling gas throughout the generator.
Body weight – A weight plug that is installed in a threaded hole in the side of the rotor forging for the
purpose of balancing out vibration patterns related to unbalance due to the length of the rotor.
30
IEEE Std 1665-2009
Brake – The device applied to a hydrogenerator/motor used to rapidly slow the drive train down to facilitate
a mode reversal in short periods of time.
Brush – A carbon compound material with a pig-tail conductor that rides on a collector ring or commutator.
The brush is specified for a particular operating environment and current density.
Brushless excitation system – A rotating exciter connected directly to the rotor through a diode wheel that
eliminates rotor brushes and slip rings.
Building bolts – Axial frame-mounted bolts to which the outer edge of each punching is keyed. The bolts
upon which the stator core is stacked.
Bump test – See Frequency response test.
Bus – A high current electrical connection of two or more circuits.
Bushing – An insulating device that permits the parallel ring extensions to pass through the generator
frame.
Bushing box – See Lead box.
C_
Circuit rings – see Parallel rings.
Coil – A unit of a winding consisting of one or more insulated conductors connected in series and
surrounded by common insulation, and arranged to link or produce magnetic flux.
Coil support braces – An insulated bracing member to which bottom coil end turns are secured. Coil braces
assist in constraining end windings from radial deflection.
Coil support rings – Glass filament rings that are utilized to restrain coil end turn movement. Rings may be
located on bottom coil sides, between bottom and top coils, or on top coil sides.
Collector end – The end of the generator where the collector rings are found. See also Turbine end.
Collector rings – Rings that permit the transfer of dc exciter current to the rotor axial leads.
Connection Rings – See Parallel rings.
Contact resistance – The ratio of the voltage drop across the contacts (from line side to load side), divided
by the current passing through the contacts.
Constant pressure brush holder – A brush holder designed to maintain the same brush pressure as the brush
wears down.
Conventional machine – A generator in which the heat generated within the stator conductors should first
pass through the major ground wall insulation before heat transfer can occur to the cooling gas.
Condol – An alloy of aluminum used as the winding conductor material of some rotors constructed in the
1950s.
Copper dusting – A condition that occurs when a rotor winding that has loose fitting conductors abrades
while the turbo-generator drive train is on turning gear.
Core – The assembly of laminated iron punchings in the generator stator that supports the stator coils and
through which the magnetic flux flows.
Core block – An insulating block, used between adjacent coil sides at the end of the stator core, intended to
provide support for the coil straight part extension.
Core bolt – See Through bolt.
Core monitor – See Generator condition monitor.
Coreplate – An insulating surface coating for electrical steel. The coreplate reduces interlaminar losses and
enhances steel punching. There are various grades available for different applications.
Coupling – The means on either end of the shaft by which the rotating generator shaft is joined to the
rotating turbine or exciter shaft.
Creep block – See Filler under wedge.
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IEEE Std 1665-2009
Crevice corrosion cracking – Deterioration that occurs in stator water box to winding conductor
connections brazed with a brazing material containing phosphorus.
Cylindrical rotor – A rotor forging with slots cut in an axial direction for rotor coils, usually of a 2-pole or
4-pole design.
D_
Damper windings – See Amortisseur windings.
Diamond area – The stator coil wraparound area that derives its name from the bottom coils being bent,
(having a “throw”) in one direction and the top coils crossing in the opposite direction giving a
crosshatched, diamond-shaped appearance. The end portions of the coils not contained in the core.
Diamond coil – See Coil.
Diamond spacer – A spacer pack or blocking utilized between adjacent coil sides in the end windings to
restrain end winding movement.
Diode wheel – See Rectifier wheel.
Double ended stator – A six phase machine comprised of three phases brought to bushings on one end of
the stator and three phases brought to bushings on the other end of the stator. These machines are
normally applied because auxiliary equipment such as bushings cannot be procured with a high
enough current rating to carry the current that would be present in a three phase machine. Note
that one phase from each end is paralleled at the isolated phase bus duct to comprise a composite
phase. The other phases are likewise paired.
Double frequency vibration – The twice-per-revolution vibration resulting from the rotor’s magnetic forces
tending to pull the stator core into a rotating ellipse.
E_
EMI (electromagnetic interference) – Electromagnetic energy from sources external or internal to electrical
or electronic equipment that adversely affects equipment by creating undesirable responses
(degraded performance or malfunctions).
End blocking – Blocking utilized at the connection area of the winding and intended to restrain these areas.
End shield – An assembly of laminated iron punchings on each end of the stator core designed to prevent
stray axial magnetic flux from causing damaging core heating.
End turn – The portion of a coil extending outside the stator or rotor slot.
End winding – See End turn.
Epoxy mica insulation system – Generator electrical insulation system using mica materials in an epoxy
resin.
Excitation system – A generator’s source of dc current for the rotor winding, and its associated control
mechanism.
Exciter – The machine that supplies dc current to the generator rotor winding.
F_
Fault – An insulation failure or breakdown in the continuity of a conductor, usually causing an electrical
device to fail to perform as required.
Fiber optic – A glass or plastic fiber that carries light along its length. Fibers are used instead of metal wires
because signals travel along them with less loss, and they are also immune to electromagnetic
interference.
Field – The magnetic field of the generator. The term is also often used to describe the generator’s rotating
element. See also Rotor.
Field winding – Synonymous with rotor winding. The winding on the rotating element that creates the
generator’s magnetic field.
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IEEE Std 1665-2009
Filler under wedge – An insulating material utilized between the slot wedge and the top coil side to secure
and restrain the coils in the stator core.
Fingerplate – A core end plate that uniformly spreads a through bolt’s clamping force over the core
laminations, especially the core teeth area.
Flexible mounting – A spring mounting system designed to prevent the vibration of the stator core from
being transmitted to the frame and foundation.
Flux – Magnetic lines of force.
Frame – The visible, outermost part of the generator that supports the stator core and bearing brackets,
forming the gas-tight enclosure containing the hydrogen.
Frequency response test – A test that analyzes the natural response of stator end windings upon excitation
with a mechanical impulse. The response is fully determined by the properties and mechanical
rigidity of the stator end winding.
G_
Generator condition monitor – A device located external to the generator but continually monitoring a
portion of the cooling hydrogen, and that activates an alarm if the gas includes any machine
thermal decomposition particles (also known as pyrolysis products).
Generator/motor – A waterwheel machine that can operate as either a hydro-turbine generator, or pump
motor by reversing the direction of rotation.
Gland seal – An oil seal at either end of the generator that prevents hydrogen from leaking out between the
rotating shaft and the bearing bracket.
Grading system – Material, paint, or taping located on the end turn of the stator coil outside the stator core.
The material has the proper resistance characteristics to provide a voltage gradient from the
grounded stator core to the surface voltage of the coil insulation in the end turn area.
Ground wall insulation – The main high voltage electrical insulation that separates the copper conductors
from the grounded stator core in motor and generator stator windings.
Gunstock brackets – The apparatus that connects the stator core and/or frame to the basket or surge rings to
support the end turns.
H_
Hollow strands – A strand may have a solid cross section, or it may be hollow—like a tube—to permit the
flow of cooling fluid in intimate contact with the conductor (one form of “conductor cooling”).
Hydrogen cooler – The generator top-mounted or bearing-straddling device in which the heat absorbed by
the gas is transferred to water flowing through numerous internal pipes.
Hydrogen pressure – The pressure, in kilopascals (or pounds per square inch), of the hydrogen gas in the
generator frame. Generator ratings are specified at one or more standard hydrogen pressures, for
example 500 kPa, 400 kPa, or 300 kPa (or 75 PSIG, 60 PSIG, and 45 PSIG). Note that a lightly
loaded generator may be operated at a lower rated hydrogen pressure to reduce windage losses and
hydrogen consumption.
I_
Inner-cooled machine – A generator in which the stator coil coolant fluid or gas flows internally through
the coils with heat transfer consequently occurring by means of direct contact between the
conductors and cooling medium.
Inner-outer frame – A generator design in which the core and stator windings are shipped separately from
the outermost protective frame.
Integral frame – A generator design in which the stator and outer protective frame are shipped in one piece.
Iron core – The assembly of laminated steel punchings in the generator stator that supports the stator coils
and through which the magnetic flux flows.
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IEEE Std 1665-2009
Isolated phase bus duct – An electrical means to connect the generator with the generator step-up
transformer. The description is usually applied to large turbine generators. This apparatus is often
called “isobus,” or “iso-phase-bus.”
J_
Journal bearing – The force-lubricated device that supports the cylindrical journal of the generator rotor
shaft.
K_
Kingsbury 16 thrust bearing – A popular thrust bearing made by Kingsbury, Inc.® 17 The proper generic
name is a “tilted pad thrust bearing”. It consists of an annular arrangement of Babbitt-covered, pie-
shaped, stationary shoes. The shoes form a circle around the rotating shaft. A cylindrical thrust
block with a highly-polished end is pressed onto the shaft and held to the shaft with half-moon
collars. The polished end of the shaft rests on the surfaces of the Babbitt-covered stationary shoes.
The shoes are mounted on spherical studs that allow them to tilt.
L_
Lamination – See Punching.
Lead box – The extension of the generator frame enclosing the generator leads.
Lead carbonate – A poisonous white power. It is created in generators by a reaction between the lead solder
used in the generator’s inner cooler, carbon dioxide, and the moisture in the generator.
Locking ring – See Snap ring.
M_
Magnetic circuit – The complete closed path taken by magnetic flux, in the stator core.
Major insulation – See Ground wall insulation.
Mica – Electrical insulating material with superior electrical insulating properties.
N_
Negative Phase Sequence Current – Generator negative phase sequence currents can be caused by any
unbalanced load condition on the system including: un-transposed lines, single phase loads,
unbalanced type line faults, and open conductors. Negative sequence currents generate a flux in a
machine that rotates backward with respect to the normal flux. The negative sequence currents can
result in dangerous overheating in critical parts of the generator rotor forging. The negative
sequence currents appear as ac currents in the rotor body and cause eddy current heating.
Neutral bus – The optional short-circuit connection device between the three neutral terminal bushings.
Neutral enclosure – The optional protective casing around the inter-connected neutral leads.
Neutral – The end of a wye-connected winding that is electrically close to ground. (In practice, most
generator neutrals are connected to ground through some type of current limiting device to limit
the line to ground fault current.)
No-load ceiling voltage – The maximum permissible exciter voltage under no-load conditions.
Nominal ceiling voltage – The maximum permissible exciter voltage under rated-load conditions.
O_
OEM – Original Equipment Manufacturer.
16
17
Kingsbury, Inc.® is a registered trademark of Kingsbury Incorporated.
34
IEEE Std 1665-2009
P_
PD monitoring – Instrumentation for measuring partial discharge in a high-voltage winding. The detector is
usually a coupling capacitor or a slot coupler.
Parallel rings – Internal generator electrical connectors on the exciter end of the stator that carry current
from the ends of the stator windings to the generator terminal bushings.
Patina – 1) The green coating that forms on the surface of copper or copper alloys exposed to the
atmosphere for a long time; 2) on collector rings, a surface film caused by a combination of
moisture in the air and carbon from the brushes.
Phase lead – The connection between a stator winding phase group and a parallel ring.
Phase rings – See Parallel rings.
Pole – The portion of the rotor encircled by the rotor winding.
Pony motor – A hydrogenerator/motor starting method where an external motor connected to the pump
motor shaft starts the pump motor and brings it up to speed before it is synchronized to the line.
Power factor – The real power to apparent power ratio; the decimal fraction multiplied by volt-amperes
equals watts.
Pressurized gap – A method of cooling the generator rotor by utilizing stationary and rotating barriers that
subdivide the cooling paths, utilizing alternate high and low pressure zones in the air gap.
PSDS (pre-stressed driving strip) – A ripple spring-like insulating material utilized as a filler between the
wedge and coil side to securely tighten the coils depth-wise in the slot.
Pumped storage unit – A waterwheel machine that operates as a hydrogenerator during peak loads utilizing
water which it previously had pumped into a reservoir as a pump motor when power demands
were light.
Punching – A keystone-shaped steel sheet, insulated on both sides, that with other such sheets forms the
generator’s core.
Purging – Removing hydrogen from the generator; scavenging hydrogen from the generator; degassing the
generator frame. The process is performed to improve hydrogen purity in the generator to reduce
windage losses and to stay out of the explosive range of hydrogen and air.
R_
RF CT (Radio Frequency Current Transformer) – a high-frequency band detector connected to a neutral
lead or ground lead for use with a selective-frequency voltmeter to detect electrical system
abnormalities that produce high RF characteristics.
RTD (resistance temperature detectors) – A resistor made of some material for which the electrical
resistivity is a known function of the temperature and that is intended for use with a resistance
thermometer. It is usually in such a form that it can be placed in the region where the temperature
is to be determined. In electric machinery these are located throughout the machine indicating
various strategic winding and iron temperatures.
Race track coil – Coils wound in a concentric oval fashion in the slots of cylindrical pole rotor.
Radial core ventilation – Cooling of stator core iron laminations by the passage of gas through radial spacer
plates located at intervals between the laminations.
Radial terminal stud – Radial connection to one of the axial leads at the collector end of the rotor (on turbo-
generators).
Retaining ring – A high-strength forged metal ring encircling the rotor end-turn windings on turbo-
generators, to restrain radial movement due to angular and radial acceleration action.
Retaining ring liner – The insulation forming a dielectric and mechanical barrier between the rotor end
windings and the high-strength steel retaining ring.
Roebel transposition – An arrangement of strands occupying two height-wise tiers in a bar (half coil),
wherein at regular intervals through the core length, one top strand and one bottom strand cross
35
IEEE Std 1665-2009
over to the other tier in such a way that each strand occupies every vertical position in each tier so
as to equalize the voltage induced in each of the strands, thereby eliminating current that would
otherwise circulate among the strands. Looking from one end of the slot, the strands are seen to
progress in a clockwise direction through the core length through what may be interpreted as an
angle of 360º so that the strands occupy the same position at both ends of the core. There are
several variations of the Roebel transposition in use. In a bar having four tiers of copper, the two
pairs of tiers would each have a Roebel transposition. The uninsulated bar, then, would be
assembled as two Roebel-transposed bars, side by side. In order to transpose against voltages
induced by end-winding flux, various modifications of the transposition in the slot, and extension
of the Roebel transposition into the end winding, have been used. Roebelling can be a 540 degree
transposition if the transposition extends into the end turns.
Rotating barrier – A forged metal ring on the surface of those rotors used in the pressurized gap cooling
scheme; also termed a baffle ring. See also Zone ring.
Rotor – That generator element that, when rotating and energized with dc current, becomes a powerful
electromagnet.
Rotor field – See Rotor.
Rotor ground – A ground between the rotor winding conductors and the rotor forging. A rotor can operate
with one ground, but a second ground can cause severe damage, as a portion of the rotor winding
will be shorted out by the second ground.
Rotor rim – The laminated portion of a generator waterwheel rotor to which the salient poles are mounted,
and that completely encircles, and is supported by, the spider arms.
Rotor winding – The winding on the rotating element that creates the generator’s magnetic field. Also
referred to as “field winding.”
Round rotor – See Cylindrical rotor.
Runner – The flanged extension of a vertical waterwheel shaft that is supported by the tilted-pad thrust
bearing.
S_
Salient-pole rotor – A rotor with individually-wound poles, usually applied on slower speed machines.
Scavenging – See Purging.
Series connection – The connection between stator coils within the same phase grouping.
Sheet insulation – The electrical insulation that is applied between turns in a cylindrical rotor.
Short circuit – An abnormal electrical connection of extremely low impedance, usually resulting in
excessive current.
Short circuit ratio (SCR) – The ratio of rotor current at no load and rated voltage to that required to produce
rated armature current under short-circuit conditions at the generator stator terminals.
Side filler – An insulating material or semi-conducting material utilized to tighten the windings widthwise
in the slots.
Slip ring – See Collector ring.
Slip stick – See Filler under wedge.
Slot wedges – An insulating and/or high-strength material utilized to secure the windings in the slot
portion.
Slots – Recessions in the stator or rotor into which coils are placed.
Snap ring – A ring that fits in a slot in both the rotor forging and in the retaining ring to lock the retaining
ring in place so that it will not migrate away from the rotor when the rotor is at speed.
Spark plug – See Radial terminal stud.
Spider – A waterwheel machine’s rotor arms.
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IEEE Std 1665-2009
Stationary barrier – A non-metallic ring on the inner bore of the stator that forms part of the barrier used in
the pressurized gap cooling system.
Stator – The stationary element of the generator magnetic circuit and its associated electrical windings and
leads.
Strain blocks – Insulating, tapered, wedge-shaped blocks utilized on the end winding between top and
bottom coil sides.
Strands – One of a number of paralleled, insulated, conducting elements that constitute one turn of a coil in
rotating machinery.
Surge rings – See Coil support rings.
Synchronous generator – A constant speed machine that is energized by a dc rotor, which keeps the
generator synchronized to the external polyphase electrical system.
T_
TC (thermocouple) – Temperature-sensing device utilized in a manner similar to an RTD but composed of
two dissimilar metals that produce a measurable voltage that varies with temperature.
Thermalastic insulation system – A coil insulation system whose coefficient of expansion approximates
that of the copper conductor, thereby minimizing temperature-induced stresses.
Through bolt – Insulated bolt passing axially through the core, uniformly clamping the punchings together.
Tooth – That portion of the rotor or stator located between adjacent slots with a high flux density-carrying
capability.
Top tooth cracking – Cracking in the rotor forging under the retaining ring. This condition is usually
repaired by installing a modified retaining ring and machining the forging in the area of the cracks.
Turning gear – Slow speed apparatus that turns a turbine generator drive train when the turbine generator is
off-line to prevent turbine rotor sagging.
Turbine end – The end of the generator where it connects to the turbine. See also Collector end.
Turbo-generator – A machine of special design intended for high-speed operation. Turbo-generators
usually are directly connected (or through a gear set) to gas or steam turbines.
U_
Umbrella-type hydrogenerator – A vertical waterwheel machine in which the thrust bearing is located
below the rotor body.
V_
V-blocks – a block having a precise V-shape for clamping or holding pole pieces.
W_
Water box – Connection to winding conductors on one end and to an electrically insulated water hose on
the other end that conducts purified water to a water-cooled stator winding.
Water-cooled machine – An inner-cooled generator whose stator windings use de-mineralized water to
remove the heat generated in the copper.
Wedge – See Slot wedge.
Winding – A grouping of connected coils.
Y_
Yoke – The portion of a laminated generator stator core, in back of the winding slots; also known as the
“back iron.”
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IEEE Std 1665-2009
Z_
Zone ring – A ring in the air gap connected to the rotor or to the stator for the purpose of creating zones for
gas coolant flow with respect to the core vent spacers and/or rotor vent ducts or gap pickup
wedges. See also Rotating barrier.
#_
18–5 retaining rings – Retaining rings comprised of a steel alloy with 18% manganese and 5% chromium,
which are subject to stress corrosion cracking. This material shall not be used for new rings.
18–18 retaining rings – Retaining rings comprised of a steel alloy with 18% manganese and 18%
chromium, which.are not subject to stress corrosion cracking.
38
IEEE Std 1665-2009
Annex C
(informative)
Generator components and auxiliaries
The replacement of high-voltage stator windings is a major maintenance undertaking. It requires the
dismantling of many components, and the removal of the rotor from the stator. The need for stator winding
replacement normally arises due to long-term operating conditions that involve thermal, mechanical,
chemical, and electrical stresses. It should be recognized that operating stresses have an aging effect not
only on the winding insulation system, but also on all generator parts. Therefore it is important to establish
the condition of all components before their reassembly following the rewind. An inspection plan that
includes careful examination and testing will determine if components are suitable for continued safe and
reliable operation.
Examples of components or systems that can be inspected/tested during major maintenance are as follows:
Baffles Bearings Blower assembly

Bolting Brackets Brakes
Brushes and brush rigging Brushless excitation system Bushings
Collector rings Coolers Coupling
Filters Instrumentation Main leads
Neutral grounding Phase rings Retaining rings
Rotor winding Seals Shaft
Soleplates Spider, hub, rotor poles Stator core
C.1 Stator frame and core [turbo-generators]
The generator stator frame supports all of the generator components. Frames for turbo-generators are
fabricated from steel plate that is rolled and welded to form the required shape. The frame usually
incorporates arrangements to support cores through steel plates attached to the core bolts/dovetails and the
outer wrapper plates. The frame also affords the provisions to accommodate ventilation/cooling features
such as coolers or heat exchangers. The weight of both the stator and rotor assemblies is distributed to the
foundation through a flanged foot along the generator frame that rests on the turbine floor.
The generator frame also acts as a sealed pressure vessel capable of withstanding maximum gas pressure.
The frame is built to provide suitable generator output leads through the lead bushings that are suitably
insulated for the rated voltages.
The stator core iron, part of the magnetic circuit, is composed of many thin punched plates or laminations
of magnetic material selected for its low loss characteristics.
Machine core laminations manufactured prior to the early 1940s were hot-rolled and have poor thickness
tolerances. Modern laminations are cold-rolled and of much better dimensional quality. Although magnetic
properties are about the same for a given lamination thickness (cold- or hot-rolled), modern coreplate
(interlaminar insulation) and thinner laminations might be a consideration to improve efficiency.
The laminations are generally in the range of 0.35 mm to 0.5 mm thick and are coated with an insulating
material such as oxide, organic varnish/enamel, or inorganic coatings. Many years ago, millglass was used.
The newer coatings are better insulators and thus reduce core losses. Inorganic coatings classified as C-5
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IEEE Std 1665-2009
core plate are of particular value if global VPI is to be used, as C-5 coreplate can survive burnout
temperatures during a rewind. Millglass (magnesium silicate) is sometimes inappropriately referred to as
waterglass (sodium silicate).
The insulated segmented laminations contain slots for generator windings. The laminations are stacked
axially with heavier laminations to support vent spacers used to form radial cooling ducts for cooling the
winding and core. Sometimes, axial vents cool the stator cores, where each lamination is punched with
additional vent holes. The inside diameter of turbo-generator stator cores usually varies from about 0.5 m
(almost 2 ft) to 2 m (about 6 ft) for 2-pole or 4-pole generators.
Generally, the stator frames are built in the factory, and cores and windings installed in the factory.
However, for the very large units, the frame may be built in the factory and shipped to the site for stacking
at the site.
The stator core laminations are stacked onto the stacking bars. As the core is stacked, pressure is applied
regularly to keep the core tight. The assembled punchings are clamped into a stiff cylindrical core by
pressure plates, and in some cases, by means of additional insulated axial through-bolts.
In order to reduce stator core end heating and associated electrical losses due to leakage flux, the end
packets of the punchings are stepped back to increase the gap between the punchings and the rotor, thereby
reducing end packet flux, which in turn reduces the end heating. The end packets are sometimes split to
further reduce eddy current heating.
Two-pole generators have stacking bars at the back of the core. These bars are attached to the frame though
spring devices to isolate core vibration caused by ovalizing forces. Higher pole generators (generators with
four poles or more) are not subjected to such forces and, therefore, the stacking bars can be solidly welded
to the frame, or flexibly mounted.
Many types of 2-pole machines include compression belts or commonly known as “belly belts” or “belly
bands” around a spring mounted stator core. The “belly belts” control machine vibration levels. It is not
uncommon to install additional compression belts if the core vibrations are excessive. Belly belts or bands
are normally not easily accessible during an inspection outage, but they should be included in the
inspection, in case of stator vibration problems, or chronic wedge looseness, and/or evidence of dusting on
the back side of the core iron.
The integrity of the core lamination insulation is checked by performing a core flux test. A low flux or high
flux (loop test) should be considered for all stator rewinds.
C.2 Stator frame and core [hydrogenerators]
The stator core and frame on a typical hydrogenerator consists of heavy steel construction made in quarter
sections, one-third sections, half sections and sometimes full sections. For cores that are not stacked
continuously, a piece of thin insulating material (often referred to as “fish paper”) is placed between
sections and then the sections are bolted together. The insulation prevents the core sections from rubbing
together. This area is known as the “split” in the machine. The stator core consists of tens of thousands of
laminations stacked in packets separated by an air vent using stainless steel I-beam spacers. The I-beam
spacers allow for air flow to travel through the core in a set direction. Laminations are typically 0.33 mm to
0.35 mm thick and insulated on both sides with an insulating material (“core plate”). The laminations that
surround the I-beams are slightly thicker (0.48 mm) to accept the spot weld that holds the I-beams in place.
All laminations are attached to the stator frame via a keybar assembly that is welded to the frame. This
assembly prevents the core from being pulled into the rotor during operation. The entire core is held under
vertical pressure by the core clamping finger plates that are secured by a large diameter nut and bolt
assembly to prevent vibration during operation. The core clamping arrangement can be integral with the
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IEEE Std 1665-2009
keybar or it can be a separate structure on the stator frame. The core clamping finger plates are typically
between 150 mm and 300 mm deep, and in some cases three or four times this width, depending on the
machine vintage and design considerations. The entire stator frame and core sit on the concrete foundation
using “sole plates.” There are various designs used to account for core expansion upon heating under load.
The intent is to keep the core from buckling. Sole plates are typically finely-machined steel surfaces bolted
to the concrete foundation that have a mating surface on the underside of the stator frame. The sole plate
assembly consists of three main parts—the steel surface on the concrete, the sole plate bolts, and the mating
surface on the stator frame. The stator is secured to the sole plate assembly using hold-down bolts. On
larger machines, there is often a radial key included as part of the sole plate assembly.
C.2.1 Stator frame inspection
Frame inspection consists of looking at key components such as the keybars, frame support beams, shelves,
split assemblies, and hold-down bolts. Note that it may not be physically possible to inspect every
component listed, due to its location in the frame or physical dimensions of the machine.
Keybars – The keybar runs the entire vertical length of the stator core. Verify that the keybar is not bent or
cracked or worn and verify the weld to the frame and shelf is not broken. This also applies to any gussets
that are welded to the keybars.
Frame support beams – These support beams are not attached to the core but act as a stiffener in between
shelves to give the frame its strength. These beams are in many forms such as angle iron or tubular. Inspect
all welds to the frame and shelf assembly to ensure no cracking and ensure no deformation is present.
Shelves – Ensure that all welds from the shelf to the stator frame are not cracked. Also, look for signs of
water leakage caused by a leaking water cooler in service, if so equipped.
Split area – Ensure that the bolts that hold the splits together appear tight and that the welds in this area do
not have any cracks. Make note of the alignment of the split in this area and reference this to the core
inspection which will be discussed later.
Hold down bolts – The stator frame is held down to the sole plate with bolts. These bolts are on the bottom
shelf of the frame and are large in size. These prevent the generator from jumping up during a fault
condition. Depending on the machine design, these bolts are either bolted solidly to the frame or there is
allowance for the frame to move radially, but not up and down, so there may be clearance between the bolt
head and the stator frame. Ensure in either case the bolts are still intact and in good condition—removal of
the bolts may be necessary.
Sole plates – The sole plate is anchored in the concrete using large, long bolts that can typically extend into
the concrete foundation by 1300 mm or more. Typically the top 400 mm (16 in.) of this concrete
foundation is notched out so that grout can be used to level the sole plate and assist in its final positioning
for level. Check the grout condition and ensure that severe cracking of the grouted area is not occurring so
as to defeat the structural integrity and purpose of the grout. A qualified civil engineer and a detailed
reference drawing may assist in this part of the inspection. If the stator has been removed from the sole
plates for the rewind, check the sole plate surface and mating surface on the stator frame for scoring and/or
rubbing points, as these two surfaces should glide smoothly together.
C.2.2 Stator core inspection
This inspection should be done in two stages. The first stage should be done when the winding is removed
but before the core is cleaned. The second stage should be done when the core is cleaned.
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IEEE Std 1665-2009
First stage: If the core was not stacked continuously, the slot that contains the split should be inspected for
signs of fretting and chevroning. Fretting occurs when the two sections of core iron are rubbing together or
laminations are vibrating and destroying themselves. Fretting can be confirmed by a reddish, rusty-colored
powder in the affected area. In the split slot, fretting would occur if the core sections are rubbing against
each other. Sometimes, depending on the machine, this powder will form a grease-like consistency due to
all the contaminants inside the machine while operating. If fretting is noticeable in the split area, repairs
should be made before the rewind begins.
The back of the core can reveal fretting as well, particularly where the laminations attach to the keybar
assembly. Again, if fretting is noticed in this area, repairs should be made before the winding begins.
Second stage: When the core has been cleaned, more anomalies could be revealed on the core surface,
inside the air ducts, and inside the slot section. Starting at the back of the stator frame, inspect the core for
buckling; this is evident by a wave in the core. There is nothing that can be done to fix the buckling but it
should be monitored to ensure it does not get worse. Using a pocket knife, take the thin edge of the blade
and try to insert it between laminations in the middle of a packet. The knife blade should not penetrate into
the laminations. If there is penetration, then the core is loose in this area and will need to be tightened
before returning to service. Take care to not over-torque the core studs. Otherwise, damage to the stator
frame may occur.
The inside of the stator bore should be inspected for split alignment, insulating separators, shorting of
laminations, slot dimension, fretted or broken teeth, broken welds on finger plates/misalignment, migrating
spacer blocks, chevrons, and signs of overheating.
The core should be cleaned using a corn cob blast, dry ice blast, or dry ice blast with solvent. The corn cob
blast works very well on cores that are greasy and full of grime. The dry ice blast works best when the
grease and grime are minimal. The dry ice blast with solvent is an alternative to using corn blast as the
cleanup is much quicker, cheaper, and less cumbersome. There has been good experience at some utilities
using solvents from the “terpene” family mixed with a petroleum distillate (aliphatic) at a ratio of
approximately 25% to 75% respectively. There are also many types of environmentally-friendly degreasers
that can be safely applied on the machine before the dry ice blast begins. Typically, a 5 to 10 minute soak
time is adequate before the dry ice blast begins. It should be noted that the flash point for the “terpene”
family is quite low; therefore mixing it with a high flash point petroleum distillate is mandatory.
Consultation with the manufacturer or distributor of the “terpene” is strongly recommended for proper
mixing and product dispensing.
Split alignment – Perhaps from day one, or over time, some split areas will misalign axially as well as in
the radial (depth) direction. There is very little that can be done to alleviate this if this has occurred. When
winding the machine, particular attention will have to be paid at the bottom packing, regarding coil fitting
and wedging.
Insulating separators – If the insulation material (sometimes called fish paper) is not present, attempts
should be made to re-establish the function of the insulation by inserting a very thin piece of insulating
material. This is particularly important if fretting was observed before the core was cleaned.
Shorting of laminations – Each lamination has been insulated from one another to control eddy currents.
If there is a suspected area where the laminations are shorted together, take a magnifying glass and verify
laminar separation. If laminar separation is not apparent, then steps should be taken to separate the
laminations.
Slot dimension – A slot gage should be used to check each and every slot for proper dimension so the new
coils can be installed with minimal trauma to the coil.
Fretted or broken teeth – The front edge of the teeth (closest to the bore face) should be carefully
inspected for any signs of fretting or broken pieces. If the core is loose, this fretting and breaking may be
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IEEE Std 1665-2009
more prominent at the top of the core directly below the clamping finger layer. Broken pieces of core tooth
can also be an indication that the core iron has become brittle and further testing may be required to
determine the mechanical and magnetic properties of the core.
Broken welds on finger plates / misalignment – Each core clamping finger plate should be inspected for
broken welds on the fingers. It is likely only the first weld closest to the bore face will be visible. Also,
fingers that are not parallel with the stator core iron should be adjusted if possible.
Migrating spacer blocks – Spacer blocks when viewed in the air gap are in a set pattern all around the
machine. If any spacer assemblies have migrated from their normal location, it is advisable that the spacer
block be returned and secured in its original location. (Not all stators have these spacer blocks.)
Signs of overheating – Inspect the face of the core for discoloration or “blueing” of the laminations. This
may be caused by local shorted laminations, perhaps within the tooth area that is not visible. This can be
caused by a loose core that is vibrating and destroying the inter-laminar insulation. Consideration should be
given to performing a “loop” or core flux test, and repairs made if the area in question is more than 5 ºC to
15 ºC hotter than surrounding areas. Details on how a hot spot is to be measured and what temperature rise
is acceptable should be determined, prior to testing. Tooth face to tooth face comparisons and bottom-of-
slot to bottom-of-slot allowable temperature rises will not be as large as tooth face to average core
temperature comparisons. Further, new core vs. old core allowable temperature rises will not be the same,
as modern cores are being designed with thinner, lower-loss steels and better core plate. Finally, not all
cores were designed to operate at the same flux level. Signs of overheating on the core ends can be an
indication of non-optimal positioning of the rotor. Consideration should be given to the position of the rotor
when re-assembly takes place.
C.3 Generator monitoring instrumentation
At the time of the generator rewind, the Owner may wish to add monitoring instrumentation that was not
installed originally. Available generator monitoring equipment includes:
C.3.1 Air gap flux probe

C.3.2 Fiber optic vibration sensors
C.3.3 Generator condition monitor
C.3.4 Partial discharge monitor
C.3.5 Radio frequency monitor
C.3.6 Hydrogen purity monitor
C3.7 Temperature monitoring
C.3.1 Air gap flux probe
The shorted turn detection probe (flux probe) system is used to determine if shorted rotor turns have
occurred. The flux probe measures flux-density changes in the stator air gap. The flux density at each rotor
slot, being a function of the number of active turns, is compared with its opposing pole slot to determine the
number of inactive or “shorted” turns.
The flux probe (sensitive to radial flux variations) provides voltage reversals at the centerline of the slots
and the centerline of the teeth. These voltage spike magnitudes are a function of the active turns in the slots
(slot leakage flux) plus a distortion factor due to the air-gap flux density waveform. The success of the
detection system requires separating the slot leakage flux data from the distortion factors.
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IEEE Std 1665-2009
The flux probe monitoring equipment is intended as a diagnostic tool; that is, data taken at various load
levels over periods of time are compared against each other to see if shorted rotor turns have developed. It
is intended that baseline data is taken when the unit is new at various loads such as 25%, 50%, 75%, and
100% rated load and stored for future comparison. Then, periodically such as on a six-month or yearly
basis, another set of data is taken and compared against the original data. Some flux probe analysis systems
also require reactive power loading at specific MVAR values, to emphasize the flux pattern for specific
rotor slots. This permits enhanced accuracy in determining shorted turns in specific rotor slots.
Shorted turns on a rotor are not a cause for an immediate shutdown or trip of the unit as some other
conditions, such as a rotor ground, would be. Rotor turn-to-turn shorts may show up as an increased need of
excitation, or as an effect on rotor shaft vibration, due to changing the thermal expansion and contraction
characteristics of the rotor winding. Neither of these effects is a need for immediate shutdown of the unit.
Rotor turn-to-turn shorts may exist for quite some time period without any noticeable effect, and before
there would be a need to take action. Accordingly, suppliers have developed the rotor flux probe monitor as
a diagnostic tool rather than as supervisory instrumentation.
C.3.2 Fiber optic vibration sensors
The monitoring of stator winding vibration levels during operation has been enhanced by the development
of fiber optic vibration sensors that permit the transmission of light encoded vibration data from sensors
mounted directly on the stator end windings to a multi-channel monitor external to the generator. The
analysis of on-line vibration data provides a tool to assist in the determination of the present condition of
components of the stator winding and the prediction of maintenance intervals based on vibration changes.
The sensor is typically a single measurement axis sensor that is mounted directly to the winding in the
direction that vibration is to be measured. An internal reed and grid assembly is resonant just above 120 Hz
so the 120 Hz vibration is amplified. The grid assembly is located at the end of the reed where the reed
movement is highest and has an evenly-spaced pattern of openings that interrupt the light as it vibrates,
causing light pulses. The number of pulses in a given time interval is proportional to the amplitude of the
vibration being measured. The vibration amplitude is given in double amplitude millimeters (or mils), and
is displayed as a digital output to the fiber optic vibration monitor.
The fiber optic sensors are typically mounted to measure radial vibration, although axial and tangential
vibration may be measured as well, depending upon the type of generator and whether there is any history
available of dynamic problems. Impact testing can be provided as an option to determine the best sensor
locations for those units where a vibrating data base is unavailable.
Sensors are permanently attached to the coil ends with epoxy-impregnated, woven-glass tape and are
typically positioned either between the top and bottom coils or on the bottom of the bottom coils in order to
avoid damage during generator crawl-throughs and inspections. Fiber optic sensor cables are typically
routed along the bottom of the bottom coil support ring, also to avoid damage.
Since the generators are filled with pressurized hydrogen, a pressure fitting that provides a hermetic seal is
required to permit the fiber optic cables to enter and exit the generator without hydrogen leakage.
The fiber optic vibration sensors are not generally used in hydrogenerators. However, they could be useful
for a long endwinding stator or during a sudden short circuit test.
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IEEE Std 1665-2009
C.3.3 Generator condition monitor for turbo-generators
A generator condition monitor (GCM) system can be supplied as an option to detect the presence of
thermally-produced particles in the hydrogen atmosphere of the generator. The two basic components of
the system are as follows:
a) The generator condition monitor that permits continuous, on-line monitoring of the particulates
b) The auto-sampler that collects vapors and particulates for further laboratory analysis
Operation of the generator condition monitor is based on the fact that very high concentrations of
submicron particles are produced whenever any material within the generator is heated sufficiently to
initiate thermal decomposition. In practice, a small flow of hydrogen is maintained through the monitor
using the pressure created by the generator cooling fan. Under normal operating conditions, a constant
detector current is established in the generator condition monitor. In the event overheating occurs and large
numbers of pyrolysis products are created, the detector current is decreased substantially, actuating an
alarm. Corrective action may then be taken before more serious damage occurs in the generator.
The generator condition monitor is physically located outside the generator frame and is connected across
the generator blower by appropriate hydrogen piping. The blower differential pressure circulates a
continuous flow of generator hydrogen gas through the monitor. As the hydrogen from the generator enters
the first chamber of the monitor it is uniformly ionized by a weak source of alpha radiation. The ionized
gas then passes through collector electrodes where all of the ions are collected; the resultant current in the
electrode circuit is amplified and continuously recorded. During normal operation, there is an extremely
low level of particulates in the hydrogen, and a constant ion current will be established. Should the particle
concentration of the gas increase (due perhaps to thermal degradation), the ion current will decrease in
proportion to the increase of particles. The monitor will signal an alarm when the ion current drops to a pre-
selected value.
The GCM may also use special paints known as tagging compounds to isolate the areas of concern. The
tagging compounds are typically applied to the stator core, stator windings, rotor body, and rotor retaining
rings.
C.3.4 Partial discharge monitor
Partial discharge (PD) has not been as much a problem in hydrogen-cooled generators as it has been in air-
cooled generators. However, it has been demonstrated that a partial discharge monitor can detect insulation
degradation mechanisms such as thermal aging, voltage stress, control material degradation, and loose bars
in the slot region.
For a large hydrogen-cooled generator, partial discharges may be detectable, and yet may not pose a
problem to the insulation in the unit. In an air environment, discharges create acidic nitrous oxides that
degrade resins in the insulation system. In the hydrogen atmosphere of the generator there has not been any
observation of this phenomenon, probably due to the very low concentration of oxygen.
The partial discharge sensors are typically mounted under the slot wedges on top of the stator bars at one
end of the stator core. The connecting coaxial cables are routed away from the stator winding to a terminal
assembly that is sealed to prevent hydrogen leakage. The sensors are distributed evenly on all three phases
of the winding. The sensor manufacturer typically has suggestions on the location of the sensors, which is
at or near the line end of each phase parallel.
Partial discharge monitoring is intended as a diagnostic tool. That is, data taken at various load levels over
periods of time are compared against each other to determine if partial discharge levels have changed over
the baseline levels.
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IEEE Std 1665-2009
C.3.5 Radio frequency monitor
There are many possible sources of arc-produced radio frequency (RF) signals in large turbo-generators.
Field tests have shown that these RF signals can be detected in the generator neutral lead and can be used to
provide warning of incipient generator faults. Measurement of these radio frequency emissions from arcs
can be used in the early detection of a developing abnormality within a generator.
The radio frequency monitor is a stand-alone unit designed to continuously monitor the radio frequency
current activity in the generator neutral. The RF monitor is designed to detect abnormal generator arcing,
from defects such as broken conductor strands, through continuous monitoring and trending of the RF level
over time. A preamplifier unit is mounted in the grounding neutral enclosure. The signal processing and
control circuitry is in the RF monitor. The RF receiver operates in hostile environments (i.e., high electrical
noise and large variations in temperature and humidity) and should be housed in a shielded enclosure that
provides protection against electromagnetic interference.
C.3.6 Hydrogen purity monitor for turbo-generators
The low density and high thermal conductivity of hydrogen makes it superior to air for use as a cooling gas
in electric power generators. Hydrogen significantly reduces the windage friction losses within a generator
thereby increasing overall plant efficiency. The supply and use of hydrogen gas, however, should not be
taken lightly. Considerations need to be made to control costs, to secure a reliable supply, to consider the
safety of the installation, and to implement the most efficient way of operating the generator hydrogen
system. Air is the most common contaminate, originating from leaking rotor shaft seals. Knowing the
purity level of the generator hydrogen helps plant operators avoid conditions that place human life and
expensive machinery at risk.
Most hydrogen monitors use the principle of thermal conductivity to measure purity. The thermal
conductivity analyzers operate on the principle of a Wheatstone bridge. A pair of glass-coated, platinum
filaments—one pair for reference and one pair for measurement—are located on each arm of the bridge. A
constant current is passed through the bridge network and in doing so, any difference between the thermal
conductivity rates of the reference gas and the measurement gas will cause an imbalance of the bridge. This
imbalance signals the difference in the thermal conductivity of the two gases, thus identifying each gas and
how much of it is present in the mixture. The display unit can be calibrated directly in terms of the
percentage of one gas with another gas.
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Annex D
(informative)
Stator rewind information
D.1 Coil construction
To reduce circulating losses in the stator coils, the coils are made of multiple strands. The strands in each
coil may be transposed in a Roebel fashion, so that each strand occupies every radial position on the coil
over the same axial length of the slot portion of the coil. The solid strand conventionally cooled coil was
used in all turbo-generators and some very large hydrogenerators until the mid–1950s and is still commonly
used for some generators that are within the scope of this material. They are termed “indirect-cooled”
because the heat generated by the electrical losses in these coils has to travel through the electrical
groundwall insulation before it reaches the cooling gas. In the 1950s the manufacturers started to place the
cooling medium inside the coil, greatly improving transfer of heat. These direct-cooled coils predominantly
used pure distilled water, hydrogen gas, or air as a coolant, although oil was used on a few early generators.
If the original winding design was made with multi-turn coils, in some cases it may be possible to modify
the design to utilize Roebel bars. The main advantage of Roebel bars is the inherently lower losses obtained
from continuous transpositions and from the elimination of turn insulation. Such a redesign should be
validated by an experienced generator design engineer. The Owner should also be advised that the stator
winding axial extended length outside of the core is generally longer for Roebel bars than for multi-turn
coils. The available room for top and bottom winding end turns shall be taken into account when it comes
time to redesign a winding. However, in some occasions, air baffles at top and bottom of the stator winding
can be modified to accommodate Roebel bars. Also, the length of the stator core shall be long enough
compared to the length required for the Roebel transposition.
Roebel bar winding design could be wave type or lap type. A wave winding has less winding jumpers than
a lap winding because the stator pole-to-pole connections are made with the winding end turns. The
counterpart of this is that more slot top bars will have to be removed when comes the time to replace a slot
bottom bar in a wave winding compared to a lap winding. Usually, each parallel circuit of wave type
winding occupies a greater percentage of the periphery of the unit than lap winding, and therefore will be
less subject to circulating currents between parallel circuits than lap winding. In either winding, the
increase of local magnetic flux in a certain section of the periphery of the stator core, caused by an air gap
non-uniformity, will be compensated by the circulating currents between the parallel circuits. This may
help to reduce the effect of this non-uniformity.
D.2 Stator winding insulation
Stator windings on smaller generators are generally manufactured as multi-turn coils or bars. Larger units
are made with one-turn coils, and universally use a Roebel transposition on the strands in the slot section of
the coil. In addition, on larger generators a transposition is made to compensate for flux leakage patterns in
the end-winding portion of the coils. Generator designers often use different methods to accommodate this
end flux without overheating. Typically a 360° or 540° transposition is used in the slot. This allows the
leakage flux at the two ends of the winding to approximately cancel each other. But the Vendor may use
strand groupings with multiple connections in the series joints to accomplish this objective.
Strand insulation is often comprised of film or glass fiber with resin used to bond the fiber insulation to the
copper strands. Also a blend of glass and polyester fibers is commonly used; the polyester fuses the strand
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IEEE Std 1665-2009
insulation system to the copper. Strand-to-strand bonding strength is important to prevent strand-to-strand
delamination, due to thermal and electromechanical forces acting on the conductors (hoop forces in the end
turn area, and bottom and side forces in the slot). Although the potential between adjacent strands is
typically only a fraction of a volt, a short circuit between strands will result in destructive current, and will
almost certainly accelerate the winding aging, and ultimately result in a failure.
In multi-turn coils, each conductor turn (i.e., bundle of strands), shall be carefully insulated to prevent short
circuits between adjacent turns. Failure of the turn-to-turn insulation will rapidly cause machine failure
because high currents will circulate between the shorted turns, resulting in arcing and very high
temperature at the site of the short circuit. The arcing turn-to-turn fault will quickly melt the copper strands.
The heat and high gas pressure will quickly destroy the groundwall insulation. This type of fault is usually
quickly detected via differential and ground-type protective relays to trip the unit. However, the arcing will
continue to cause damage until the energy in the field is dissipated. Turn-to-turn faults will usually cause
core melting. If the machine is not quickly tripped, the fault can sometimes spread to adjacent coils,
causing very serious short-circuit currents and extensive damage. Although the normal operating voltage
between turns is low—generally less than a few hundred volts—the coils near the line end could be
subjected to much higher steep-fronted voltage surges during switching operations. Thus, at a minimum,
the coil turn-to-turn insulation shall be designed to briefly withstand these surges. Insulation coordination is
required between machine surge capacitors, surge arrestors, and coil turn-to-turn insulation levels. For all
machines rated 4160 V and higher, each turn is usually insulated with mica tape that provides excellent
dielectric strength as well as long-term resistance to partial discharges. The groundwall insulation is applied
over the strand and turn insulation, if present, to prevent breakdown between the energized conductor and
ground or a second phase. The groundwall insulation shall, therefore, have sufficient long-time dielectric
strength to withstand normal line-to-ground operating voltage, as well as moderate transient overvoltages.
The turn and groundwall insulation of stator windings is usually comprised of mica with organic
reinforcing, bonding, and impregnating materials. Machines in service today were typically manufactured
using asphalt, polyester, or epoxy resins. Windings manufactured at present will typically use mica tape
that is impregnated and bonded with a very high quality epoxy resin. The mica tape will often be reinforced
by a thin glass tape to facilitate application of the insulating tape and to mechanically re-enforce the
groundwall structure.
D.2.1 Groundwall insulation materials
D.2.1.1 Mica
Mica’s unique combination of electrical, physical, and thermal properties has made it vital to high-voltage
stator insulation systems. Mica is highly resistant to erosion by prolonged electrical discharge (partial
discharge—PD); no other material known to man has PD resistance approaching that of mica.
In its natural form, mica is difficult to apply to components in a continuous manner. Mica separates very
easily and has to be physically supported in some way, to stop it from delaminating. One method of
application is to build up mica flakes or splittings onto a fabric or glass backing, usually with a binder. The
mica tape can then be wound onto the surface of a conductor to form an insulating layer. Another method
of application involves the manufacture of mica paper in which mica flake material is exfoliated into very
tiny plate-like particles and formed into sheets by settling from suspension in a machine similar to a normal
paper-making machine. The cohesive force between the platelets is sufficient to give mica paper the
strength to permit gentle handling, but its tear strength is too low for most purposes until it has been treated
with a binding resin. The use of a binder limits the useable temperature of the mica tape to the maximum
that the resin will withstand.
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D.2.1.2 Bonding materials—asphalt
From the 1920s to the 1960s, asphalt-based compounds (also referred to as asphaltum and asphatum) were
used extensively as bonding and impregnating agents in the groundwall insulation of high voltage stator
windings of small- and medium-sized generators. Furthermore, asphalt was used by some small
manufacturing firms into the mid–1980s. Many generators and motors from this era are still in service
today, particularly those that have operated with moderate levels of thermal and electrical stresses.
The asphalts used in electrical insulation are black to dark brown solids or semisolids at room temperature.
They are thermoplastic, cement-like, and gradually liquify when heated. The physical properties of asphalt
significantly decrease with increasing temperature, restricting its use to Class 130 (B) applications. When
exposed to higher temperature, the lower viscosity of the asphalt results in low mechanical stability of the
insulation system. This soft insulation can then allow outward migration of the groundwall insulation in the
slot when a generator is subject to cyclic loading. The mechanisms involved in the migration are several
and complicated, but the net result is asphalt flowing out of the core slot area, thereby causing a bulge just
outside the stator core boundary. This causes tape separation. With time, the asphalt dries out in this area
and results in a delaminated, brittle, bulging area and the formation of cracks. The plastic nature of this
insulation causes the groundwall insulation to bulge out slightly into the air vents, thus firmly locking the
coil in the slot and thereby protecting this insulation from damaging slot discharges. The delamination and
cracking is often referred to as “girth cracking.”
D.2.1.3 Bonding materials—polyester
Early electric machines were insulated using naturally occurring materials (e.g., air, mica, asphalt) or those
that were easily derived from natural sources (mineral oil, shellac, rosin, oleo varnishes, and cellulose). The
steadily increasing demand for higher operating temperatures and voltage gradients, however, compelled
the development of insulating materials of greater thermal, mechanical, and electrical stability. In the 1940s
and 1950s, advances in polymer chemistry made possible the commercial use of synthetic insulating
compounds, such as polyester and epoxy resins. Polymers are generally subdivided into two broad
classifications: thermoplastic and thermosetting. Solid materials that soften and melt reversibly are
categorized as thermoplastics. In contrast, thermosetting materials undergo a chemical reaction upon
heating and become a solid that does not soften upon subsequent reheating unless heated to destructively
high temperatures.
Polyester resins may be either thermoplastic or thermosetting, depending on their molecular structure.
Thermoplastic polyesters, such as Mylar® 18 and Dacron® 19 , 20 are flexible and elastic. The use of
thermoplastic polyesters in high temperature applications (e.g., continuous operation above 150 °C) may be
limited by their thermoplasticity. Thermosetting resins are hard and strong, although some types may
exhibit excessive brittleness.
Generally speaking, polyester resins are relatively inexpensive and characterized by good electrical
properties and good resistance to heat and mechanical impact. However, some polyester resins are sensitive
to chemical reaction with moisture that can cause both electrical and mechanical degradation. While
windings manufactured with polyester resins have given good operating service at moderate design
demands, other more sophisticated resins were developed with improved physical and electrical properties.
These materials have largely superseded the polyester material groundwall insulation systems.
18
Mylar® is a registered trademark of E. I. du Pont de Nemours and Company.
19
20
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IEEE Std 1665-2009
D.2.1.4 Bonding materials—epoxy
Epoxy coatings and impregnants have been widely used since the late 1950s. Epoxy resins are valued for
their good electrical properties, improved mechanical strength, good adhesion to most materials including
metals, and resistance to moisture, solvents, and other chemicals. Hard, thermosetting insulation systems
(whether polyester or epoxy) have proven to be vulnerable to mechanical wear and cracking. Thus, it is
especially important that care be used when handling coils with this type of insulation.
D.2.2 Groundwall manufacturing processes
Groundwall insulation may be applied using either resin-rich B-stage tape or vacuum pressure
impregnation (VPI) techniques. Regardless of the manufacturing method used, an appropriate stator
winding design, high quality materials, and careful control of the production process are essential for good
results.
D.2.2.1 Resin-rich systems
In “resin-rich” systems, resin is applied to the tape during the manufacture of the tape and is partially cured
on the tape. When a tape is pre-impregnated, the resin may be mixed with a volatile solvent; alternatively
no solvent may be used and the resin softened by moderate elevating of the temperature. The tape with a
flexible B-stage resin is lapped onto the conductor assembly. The insulation system on the coil is then fully
cured, typically in an autoclave or in a press, at elevated temperatures.
An alternate to this system involves only partially curing the coil insulation in the autoclave. The coils are
then inserted into the slots in a B-stage cured state. After the winding is installed, the stator is placed into a
large oven where the insulation is fully cured.
Different processes are used by the various OEMs to remove volatiles and cure the insulating materials.
These processes are proprietary, but in every case shall be strictly followed with close quality control
procedures to provide a quality insulation system.
D.2.2.2 Vacuum pressure impregnation
For the vacuum pressure impregnation process, a dry or lightly impregnated mica tape is wound around the
conducting components, which are then put into a vacuum pressure tank. The tank is first evacuated to
remove air and volatiles (including water vapor from the insulation). The tank is then filled with low-
viscosity impregnating resin under pressure. When the interstices of the groundwall are filled with resin,
the coil is removed from the tank and heated under pressure to complete the cure of the resin and accurately
mold the coil.
Epoxy resins to be used as impregnants for the mica tape shall have sufficiently low viscosity to fully
permeate the taped layers and completely fill inter-layer spaces. As with “resin rich” systems, these process
are proprietary, but in every case shall be strictly followed with close quality control procedures to provide
a quality insulation system.
D.2.2.3 Global vacuum pressure impregnation
For convenience of manufacturing process, a variation on VPI coils was developed. For this process, a
lightly impregnated uncured mica tape is wound around the coils. The coils are then wound into the stator.
The entire stator is then placed in a tank sufficiently large to accept the stator. In this vessel, the assembled
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IEEE Std 1665-2009
coils are exposed to high vacuum followed by resin impregnation. The stator is placed in a large oven and
heated to complete the cure of the resin. The size of machine that can be manufactured in this manner is
limited by the size of the VPI tank. As with the previously described systems, these process are proprietary,
but in every case shall be strictly followed with close quality control procedures to provide a quality
insulation system.
It should be noted that rewinding a global VPI generator might be complicated, because removing the coils
from the stator core can be extremely difficult. A burnout process can be used to remove coils. However,
maximum burnout temperature shall not exceed maximum core plate allowable temperature. Water lancing
has also proved to be an effective means of removing the resin bond between VPI coils/bars and the stator
core to facilitate winding removal.
D.2.3 Thermal ratings
Thermal aging of the electrical insulation is an important factor in determining the life of motors and
generators. The rate of insulation deterioration due to thermal aging increases rapidly with an increase in
temperature. Thus, insulation temperature limits should be selected so that the equipment will provide a
satisfactory service life under normal operating conditions. In addition to the stator winding, all materials in
the slot section including wedges, under-wedge springs, side fillers, and spacers shall meet the specified
temperature rating. However, wedges are well-ventilated and are far from the hot spot, and they may not be
of the same temperature class (G-10 material).
D.2.3.1 Hottest-spot temperature
It is not practical to actually measure maximum insulation temperatures due to inaccessibility of the
insulation that is in direct contact with the copper conductor. Therefore, the hottest-spot temperature of the
insulation shall be derived from calculations and from the observable (measurable) temperature and a
hottest-spot allowance.
To measure the insulation temperature, embedded temperature detectors (i.e., thermocouples (TCs) or
resistance temperature detectors, (RTDs)) are located between the top and bottom coil sides in a slot of
indirectly-cooled generators. Many Owners prefer to install temperature detectors in slots where the two
bars are from the same phase or the same parallel circuit. Some of these detectors are located about
midway, axially, in the machine where the highest temperatures are normally expected to occur. In most
cases, this provides a good indication of the hottest area in the stator. Large hydrogenerator machines may
be equipped with more than twenty-four temperature detectors distributed around the circumference of the
machine. The hottest-spot temperature may be estimated by adding a “temperature allowance” to the
temperature as measured by the temperature detector or estimated by more sophisticated monitoring
systems. The hottest-spot temperature allowance may be designated, but the value is somewhat arbitrary
because it is difficult to accurately determine as it depends on many design factors of the stator, e.g., slot
width and insulation thickness. (10 ºC is quite commonly used.) It is a good practice to install temperature
detectors in slots where the two bars are from the same phase or the same parallel circuit. There are other
factors that affect the temperature rise in each coil including such things as whether or not it is terminated
with a phase ring.
D.2.3.2 Insulation class
Generators are generally specified according to ambient temperature and insulation class. Ambient
temperature refers to the cold gas temperature of the cooling medium in the generator. An ambient
temperature of 40 °C is normally taken as the highest temperature at which the equipment is expected to
perform as specified. Machines operating above 1000 m (3300 ft) require special considerations.
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IEEE Std 1665-2009
The stator winding of an indirectly-cooled generator is often equipped with embedded temperature
detectors to measure the operating temperature between coil legs in the stator core slot. These monitor the
winding’s observable temperature and are used to protect the machine. The difference between the
observable temperature and the temperature of the cold air or gas entering the machine from coolers or the
environment is the temperature rise of the winding at the RTD location. The rated temperature rise is
specified over cold gas of 40 °C. The observable temperature will have a limit determined by the Vendor
based on test and calculations of the hottest temperature of the winding known as the hot spot temperature.
The hot spot is not easily measured; therefore, a safe margin is established by the Vendor between the
observable and the hot spot. The hot spot temperature shall not exceed the winding insulation temperature
rating or class to have normal life. A Class 155 (F) insulation is rated for continuous hot spot operation at
155 °C or 115 °C rise over 40 °C cold gas. A safe observable temperature for this insulation class could be
specified by the Vendor around 120 °C or 80 °C rise over 40 °C cold gas. IEEE Std C50.12 and IEEE Std
C50.13 specify the observable temperature rise limits for salient-pole and cylindrical rotor synchronous
generators. The normal practice is to install windings of a higher temperature rating in order to have an
increase in the life of the insulation and to protect against temporary temperature overruns.
NOTE—For direct-cooled coils, IEEE Std C50.13 does not require the manufacturer to install embedded temperature
detectors (RTDs or TCs) in the stator slots. Instead, it only stipulates temperature detectors at the coolant discharge. If
the Owner wants temperature detectors embedded in the stator slot, they shall be specified.
When rewinding a stator there may be an opportunity to improve the temperature class of the insulation
system. Older generators were equipped with windings having Class 130 (B) insulation or lower. A typical
replacement winding will have Class 155 (F) insulation that can operate continuously with normal life at
higher temperature. However, changing the insulation class of the stator does not change the specified
operating temperature of the machine. For example, the specified operating limit of the rotor winding could
be exceeded before the new stator winding temperature limit is reached.
D.3 End winding support (for hydrogenerators)
The stator end winding is the portion of the coil or bar that is outside the stator core slots. Support for this
area is needed to prevent excessive movement during fault conditions or sudden load changes and to keep
the coils from shifting downward due to gravity. For hydrogenerators one or two circular insulated metallic
non-magnetic rings (surge rings) are a common method for radial support. Resin/fabric composites are also
used as ring materials. The winding is usually lashed to the support rings. Spacers between the winding
itself are installed to manage forces between coils.
During a maintenance outage for winding replacement, the winding supports should be addressed. The
insulation on the support rings should be inspected and possibly replaced, and if the ring position is not
optimal for the new winding shape, the ring system should be relocated or renewed. Spacers between coils
should be installed with the new winding. Since the support system is designed for very high forces, the
design should only be changed through consultation with the Vendor.
D.4 Stator slot support systems
By the nature of the currents induced in the stator coils, there will be a tendency for undesirable movements
in the coils. This movement is associated with attractive and repulsive forces, and thermal expansion and
contraction. These forces will be amplified in times of phase-to-phase short circuits.
This propensity to move should be compensated for or prevented by what is termed a wedging system.
Wedging systems are support systems to the stator coils that keep them tight in their slots. They consist of
slot fillers and wedge tension devices.
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IEEE Std 1665-2009
Slot side fillers are used to hold the stator coils tightly in the slot laterally and to insure good contact with
the core. These materials can be made of strong resin-filled glass weave material. They also contain some
type of a semi-conducting agent to aid in the electrical contact between the stator coil and the core. The
filler may be a flat thin strip, or fleece. But a ripple-spring design is now commonly used to provide
continual pressure. Use of elastomeric conductive silicone as side filler (fixed to the coils) is also a proven
way to pack the stator winding.
Wedge tension devices are the top pieces that hold the stator coils and side fillers tightly in the slots
radially. They may be a single piece, double, or multiple-part systems. They typically consist of a sub-
wedge(s) of various tapers placed each on top of the stator coil to accommodate the slot geometry, building
layer(s) up to the tooth top. The top-most wedge is driven axially along the taper of the tooth, holding the
whole assembly rigidly in place.
D.5 Vibration concerns
Vibration is a concern because if left unchecked it can adversely affect the frame, core, stator windings, and
rotor assembly. Vibration is generally caused by unbalanced forces, be they magnetic, mechanical, or a
combination of forces.
Rotating magnetic forces due to unbalanced magnetic fluxes affect the stationary parts of the generator
such as the frame, core, and stator windings. Thermal (shorted rotor turns) and mechanical stress
unbalances are usually found to be the causes of excessive rotor vibration.
As the topic of generator vibration is quite extensive and many topics are beyond the scope of this
document, only the effects on stator windings shall be covered.
An unbalanced magnetic attraction is placed on the core, stator coils, and frame by the nature of the
magnetic flux linkages coming from the current in the rotor. This vibration manifests itself as a twice line
frequency vibration. The stator bars are held securely in the slots, but when they exit at the ends of the core,
they can touch and easily abrade away their insulation due to these vibrations, changes in load, or short
circuits. To prevent this, the individual coils are held apart by insulating separating materials and rigidly
tied together into a solid immovable mass. This is known as end-winding blocking and roving. It is
customarily part of a rewind project. The work is time-consuming and should be done carefully and
thoroughly. Each manufacturer may have a different method of accomplishing this, and should be
consulted for details. However, some Vendors do not use any ties in their standard endwinding design. If
the Owner desires endwinding ties, they should be included in the technical specification.
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IEEE Std 1665-2009
Annex E
(informative)
Cylindrical rotor rewind information
E.1 Rotor forgings
Some small early (pre 1940) rotors were built using a laminated construction similar to that used on
induction motors. However, since that time most rotors have been constructed from a solid forging. Most
rotors today are vacuum cast of a nickel-molybdenum-vanadium alloy. The chamber is maintained at a
vacuum while pouring to remove hydrogen, oxides, and other fissure-producing materials. Resulting high-
quality homogeneous castings are then forged and machined to the final dimensions. Rotor “blanks” may
weigh up to 180 metric tons (200 tons [US]) for very large generators. Lengthwise slots are then machined
to receive rotor windings.
The forgings for these early machines were produced using less sophisticated methods than used today and
hence may have a higher impurity content. This means that highly stressed regions may be susceptible to
cracking.
The most common areas for cracks to appear are in the teeth immediately under the retaining ring, and the
vent holes in the body of the forging. Other areas where cracks can occur are holes that contain the rotor
leads, and areas under large shrink fit hubs or in the rotor bore. For that matter, cracks can occur at almost
any contour or change in section modulus that can act as a stress concentrator.
Smaller and older generators have ventilating slots or cooling ducts, which are cut parallel to the coil slots.
The heat generated in the rotor coil is conducted through the slot insulation, into the rotor forging, and then
to the cooling gas in the ventilating ducts (see Figure E.1). These rotors are referred to as “indirect-cooled.”
Figure E.1—Indirect-cooled
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IEEE Std 1665-2009
As generators get larger, the slot insulation is also a primary thermal barrier that inhibits the heat
dissipation. In order to increase the current-carrying capacity of the rotor windings, most Vendors use an
arrangement whereby cooling gas flows directly through the rotor conductors. The cooling gas (air or
hydrogen) is directed axially down a sub-slot, which is beneath the conductors. The gas then discharges
radially through holes in the copper winding and into the air gap. Of course the size and contour of the
subslot, and the size and number of radial holes in the copper are critical design parameters chosen to keep
the rotor temperature within its material limits.
E.1.1 Tooth top cracking
Tooth top cracking occurs where the retaining ring fits onto the rotor body. The teeth experience a high
compressive force when the machine is at standstill, and when in operation the pressure from the retaining
ring relaxes but the load from the rotor coil under the wedge increases. So for a machine that experiences a
high number of starts and stops the cyclic stress loading can cause cracking of the tooth. The crack usually
initiates on the radius of the wedge groove where the tooth cross section increases, as shown in Figure E.2.
Figure E.2—Tooth top cracking
The cracking can be identified by a visual inspection of the suspect areas or by non-destructive inspection
techniques such as eddy current, dye penetrant, or wet magnetic particle. Small cracks can be repaired by
grinding and contouring the affected area. Larger cracks can be repaired by modifying the tooth and
installing modified wedges and modified retaining rings.
E.1.2 Vent hole cracking
Vent hole cracking results from fatigue of the rotor body where the vent holes are located in the tooth
portion of the rotor body. If not detected in its early stages this type of cracking can lead to catastrophic
damage that would necessitate replacement of the entire forging. The cracks can occur as circumferential
cracks originating in the axial vent holes, or as radial cracks originating at the bottom of the slots around
the cooling channel at the base of the radial cooling holes.
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IEEE Std 1665-2009
E.1.3 Bore cracking
Many rotor forgings have a bore down the center. The bore was created when inhomogeneous material and
debris were removed after the casting process. The machining ridges and possible corrosion sites act as
stress concentrators leading to crack initiation. These cracks develop when the rotor is on turning gear, or
during start up or shut down. Like vent hole cracks, if not identified early these cracks can lead to a
replacement of the forging. As with most other forms of cracking they can be identified using non-
destructive tests such as ultrasonic testing. Minor cracks are repaired by machining or grinding the bore to
remove the cracks and leave a smooth surface.
E.2 Rotor winding
The windings of a cylindrical rotor used to produce the magnetic field are of a multi-coil single circuit
design that is energized from a dc excitation source (typically 250 V dc to 650 V dc) either via rotating
rectifiers or a static system with slip rings outside of the generator bearings.
The windings are connected as either a 2-pole or a 4-pole, dependent upon the speed of the machine. The
relationship between the speed of the machine and the number of poles is shown in Equation (E.1) for 60
Hz machines, and Equation (E.2) for 50 Hz machines.
n = 7200/Number of poles (for 60 Hz machines) (E.1)
n = 6000/Number of poles (for 50 Hz machines) (E.2)
where n is the speed of the machine
E.2.1 Indirect cooling
The dielectric barrier on the solid copper conductor rotor windings used in smaller machines was not only
the primarily insulation barrier, but also a thermal barrier for the dc current. As the field current increases
for larger machines, the need increases for alternative cooling systems.
E.2.2 Direct cooling
The rotor winding on direct-cooled rotors consists of formed turns made from extruded copper or drawn
copper tube, rectangular in shape. Each turn consists of either a solid hollow copper conductor or two
shaped copper sections, typically U or E shape, that are placed together to form a hollow conductor that
coolant can pass through. Along the length of the formed turns, holes are machined and baffles (flow
restrictors) are placed to allow coolant to be directed through the coils in accordance with the cooling fan
arrangement for the particular machine. The individual turns are insulated from each other and arranged to
form a complete stack of nominally 6 to 8 turns within each of the rotor slots. These stacks are then brazed
to form concentric coils, and once one half of the rotor is connected this becomes a pole.
E.2.3 Turn insulation
There are four common types of turn insulation systems: taped turns, slot strips, all strips, and consolidated
coils. The first three rotor coil insulation systems are carried out by placing turns individually into the rotor
slots and progressively building up turns and insulating them within the slot. The fourth technique involves
manufacture of the turns external to the rotor slot and then placing a completed consolidated stack of turns
into the slot.
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IEEE Std 1665-2009
E.2.3.1 Taped turns
The first type of insulation system involves a style where every other turn is taped, including the end turns,
with a half-lapped glass-backed mica tape. This system is the least costly but most labor intensive (hand
taped). The tape is applied prior to inserting the coils in the slots, and provides the most protection against
contamination. The disadvantage of this system is that it requires narrower copper in the slot section
because tape adds to the coil width.
E.2.3.2 Slot strips
The second system consists of strips of glass insulation in the slots and taped insulation on the end turns.
An epoxy glass slot filler piece is inserted into the bottom of each slot, which bridges the rotor sub slot
section, if present. Then, insulated molded slot liners (commonly termed, “troughs,” “slot cells,” and “slot
armor”) are inserted into the rotor slot to insulate the copper turns from the steel rotor body, preventing the
risk of a rotor ground fault occurring. These liners usually have cuffs on the outer edges, or some other
mechanical restraint, to prevent shifting during operation. The copper turns are then stacked, one at a time,
into the rotor slot section, and epoxy glass separators are used to insulate the turns from each other. At the
top of the slot, epoxy glass or Nomex® 21,22 insulation creepage blocks are placed.
NOTE—Older rotors used rubberized asbestos separators between turns.
E.2.3.3 All strips
The third system consists of the same slot liners and epoxy glass separator strips in the rotor slots, and
strips of insulation on the end turns. This system provides the least protection against contamination.
E.2.3.4 Consolidated coils
In a consolidated coil system, turns are manufactured, assembled, and consolidated outside of the rotor slot
section using molded epoxy glass boards and separators and using epoxy resin bonding techniques. The
whole turn is then consolidated in a heated press and then electrically tested (interturn and overpotential)
prior to insertion. The consolidated turns are pre-manufactured to the exact dimensions of the slot section
and are then lowered into the rotor slot to allow connection and wedging, with only the endwinding section
connections requiring insulation. To provide a snug fit into the rotor slot, the winding is configured in a
wedge shape to match that machined into the rotor shaft, with the narrow dimension at the bottom of the
slot.
E.2.4 Slot wedges
Dove-tail wedges of either magnetic or non-magnetic steel, or aluminum are used to secure the coils into
the slots; these retain the winding tightly in the slots to reduce the effects of radial acceleration type
centripetal forces during operation. Wedges are usually of short length, although there are certain designs
of rotors that use a continuous full-length aluminum wedge.
21
Nomex® is a registered trademark of E. I. du Pont de Nemours and Company.
22
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IEEE Std 1665-2009
E.2.5 Endwinding turns and packing
Figure E.3—Endwindings
E.2.5.1 Endwindings
The end winding turns are concentric in shape and are in parallel with the shaft leads, and an annulus is
incorporated into the end winding to allow for the passage of coolant gas. See Figure E.3. The gaps
between adjacent coils are blocked using glass fiber blocks. Older machines used an asbestos fabric to act
as a conformable packing, whilst some modern machines utilize a conformable woven impregnated tape or
solid blocks with felt.
At the turbine end (or non slip ring end), the turns are connected together to the adjacent turn to form a
concentric shaped coil.
At the collector end (or slip ring end) of the machine, the copper turns are brought out into the end winding
area and connected (brazed) together progressively with step up joint blocks to the adjacent turn above.
Crossover connections are used to connect the top and bottom turns to the adjacent coils to form a
concentric winding.
Connection between the pole windings is made by a flexible copper strap, which is brazed to the bottom
turn of the outermost coil at each pole at the slip ring end of the rotor shaft. This strap is often of an omega
shaped ( Ω ) design and allows for expansion and contraction forces between the two poles. See Figure E.4.
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IEEE Std 1665-2009
Figure E.4—Pole jumper
The endwinding at both ends is packed between coils using various insulated molded packing pieces and
blocks so that the coils remain separated, and these are carefully inserted so that they are not dislodged or
fret as a result of the angular and radial acceleration related forces imposed during run up, overspeed
testing, and operation.
E.2.5.2 Rotor endwinding retaining ring Insulation
Each rotor endwinding retaining ring is insulated from the rotor winding by means of epoxy glass
laminated liner that is molded to fit the internal dimensions of the retaining ring, and then machined to the
diameter of the rotor endwinding. (For older rotors, a lining of phenolic-laminated asbestos paper and
fabric were molded to the ring under pressure). The retaining ring is usually coated with a layer of resin
varnish prior to fitting of the liner to prevent stress corrosion cracking.
Some manufacturers also provide an insulating slip layer between the endwindings and the end retaining
ring to allow for relative movement and expansion of the copper windings compared to the steel ring.
E.2.5.3 Rotor leads
Rotor leads run along the body of the rotor in two diametrically opposite longitudinal slots machined into
the rotor shaft, and connect the pole connections to the radial terminal studs. These leads are made from
laminated copper and are insulated from the rotor shaft, they are held in place by dove tail slot wedges.
E.2.6 Copper damper winding
On some designs of turbo-generator rotor, a copper bar is placed on top of the coils to prevent damage to
the insulation system during wedging; this copper bar also acts as a damper winding. Other designs use a
copper fingerplate under the end bell area as a damper winding. The need for a damper winding is
dependent upon the negative sequence design.
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IEEE Std 1665-2009
E.2.7 Radial terminal studs
Two radial connections are provided diametrically opposite to each other via holes drilled radially through
the rotor shaft, outboard of the retaining rings at the slip ring end of the shaft.
These connection studs are typically made from steel or high strength zirconium copper alloys with silver-
plated thread portions at each end to allow connection to the slip rings and main leads to the winding. The
studs are insulated from the rotor shaft by means of a pre-impregnated glass sleeve, which is bonded to the
stud and machined to the diameter of the hole in the shaft.
Silicone rubber “O” ring seals, or chevron style seals, are fitted onto the terminal studs to allow for a gas-
tight seal around the stud and the shaft.
E.2.8 Main leads, bore copper, and insulation
The radial connections from the slip rings and the radial terminal studs from the rotor winding are
connected together via two copper links of segmented cross section (D leads), that run through the bore of
the machine, insulated from both the rotor body and each other. These are typically in two sections with
flexible copper links to allow for expansion and contraction, along with angular and radial forces on startup
and during shutdown. Holes in the segmented tube correspond with the positions of the radial terminal
studs to allow connection. The main leads are inserted up the center of the bore of the rotor, and once fitted
are sealed into position using an insulated plug though the center of the bore.
E.2.9 Retaining rings and zone rings
The most highly stressed component in the generator is the retaining ring on the rotor. (This component is
sometimes referred to as a “rotor end cap.”) Its purpose is to restrain the centripetal forces of the rotor
winding end-turns. Its strength determines rotor diameter limits. Generator retaining rings come in two
basic types: magnetic and non-magnetic.
The magnetic rings are typically made of high strength low alloy steels and are used on most generators
before 1950. They are often referred to as “mag rings,” and are still used on small air-cooled generators
today. Magnetic rings are usually painted to prevent rust and corrosion. These rings are not suitable for
hydrogen-cooled machines because they will absorb the hydrogen and fail in a brittle fashion.
The non-magnetic, or austenitic, or “stainless” rings are generally found in both hydrogen-cooled and air-
cooled machines. There were several alloys used. The most common alloy was 18% manganese and 5%
chromium. These are commonly referred to as “18Mn 5Cr” or “18-5 rings.” Other alloys included 18Mn
4Cr; and several nickel (Ni) alloys: 9Mn 6Ni 4Cr, and 8Mn 8Ni 4Cr. All of these alloys are susceptible to
stress corrosion cracking. In the mid 1980s, after several violent failures, all the generator manufacturers
changed to an 18% manganese and 18% chromium, or 18Mn 18Cr material, because it has superior
corrosion properties, similar to common stainless steel. The higher chromium content makes the material
more resistant to stress corrosion cracking.
In the 1970s there were five failures of 18Mn 5Cr retaining rings where the ring actually burst. Each of
these major failures resulted in catastrophic damage to the generator and surroundings. While there have
been only a few catastrophic failures, which represents a very small percentage of the total number in
service, the resulting damage is so extensive that the Owner should seriously consider the risk of continued
operation with these retaining rings. There have also been hundreds of reported cases of severely corroded
and cracked retaining rings wherein the cracks were of such a depth that the rings had to be replaced.
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IEEE Std 1665-2009
A rotor rewind or re-insulation is an ideal opportunity to replace the retaining rings. Many generator
Owners have already replaced their 18Mn 5Cr rings, as time and budget permits. However, in some cases,
it may not be economically attractive for the Owner to replace retaining rings that have been operating
satisfactorily, and have not been subject to moisture. (There are still many generators with 18Mn 5Cr rings
in service.) In reaching the decision to replace the retaining rings, the Owner is faced with divergent and
conflicting alternatives. In the final analysis this is a risk-assessment decision. Depending on the
importance of a particular machine to the system and other business and economic factors, judgment should
be made between the options of re-using the existing rings with the risk of a catastrophic failure, or making
the investment and replacing the rings.
Zone Rings have different names throughout the industry. The purpose of zone rings is to segment or
separate hydrogen zones in the machine air gap such that the flow of coolant through vent spacers and rotor
cooling ducts is in the desired direction. Zone rings may be mounted on the rotor or on the stator, or both.
They perform the same function in all cases.
E.2.10 Fans and blowers
Forced cooling is required to remove the copper losses in cylindrical 2- and 4-pole rotor windings. A few
water-cooled rotors have been built but the majority of machines rely on fans to ventilate rotor windings
with air or hydrogen. A common design employs two shaft mounted axial flow fans, one at each end of the
rotor. Each fan consists of forged aluminum blades that are bolted and fitted to the rotor forging. The fans
force gas under the retaining rings to cool the copper winding, as well as down the air gap between rotor
and stator.
Gas flow down the air gap is often needed to ventilate the stator core and remove iron losses. Some designs
use a centrifugal type fabricated steel fan at each end to provide gas flow. Generators with direct gas cooled
stator windings may use a multistage axial flow compressor mounted on the turbine end. In this case
ductwork in the frame directs gas to the exciter end of the stator for rotor cooling. If the cooling
requirements are high there may be additional fans placed under the rotor retaining rings to help increase
gas flow across the windings through the rotor ventilating slots and cooling ducts.
Fan blades are highly stressed, and not all designs of hydrogen-cooled generators can operate in air for
lengthy periods of time. Redesigning the fans for increased rotor winding cooling is possible but not
usually attempted. During a major overhaul the fans should be inspected for cracks or loose components.
Dye checking for cracks and a visual inspection for loose or damaged components can be scheduled when
the rotor is removed for rewinding or stator repairs. Most fan designs have proven to be trouble free;
failures are rare but not unknown.
E.2.11 Collector rings
Collector rings (also known as “slip rings”) are used on all generators except those with a brushless exciter.
The two rings are typically steel forgings shrunk over insulated rings, which in turn, are shrunk on the rotor
shaft. Collectors are located outboard of the bearings and seals in hydrogen-cooled generators, and usually
inside the bearings in air-cooled units. They usually have a helical groove machined on the outer surface to
distribute currents over the collector and brush surface. The collector assembly is held by a bolted shaft
extension and is often equipped with a small fan to ventilate the rings. The collector rings are connected to
the positive and negative coils of the rotor by a dual insulated bus that runs down the center of the shaft,
and is often referred to as the “bore copper;” see E.2.8.
Collector rings are subject to scoring and wear, if the brushes make contact at the same point on the ring
each cycle. These problems require that the collector rings should be machined down during maintenance
outages. The finished refurbishment should re-establish a run-out that is within the manufacturer’s
tolerances. After a number of refurbishments, the collector rings should eventually be replaced.
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IEEE Std 1665-2009
Annex F
(informative)
Salient-pole rotor rewind information
When driven by a prime mover, the rotor (sometimes called the field, or rotor field) of a synchronous
generator rotates within the stationary component (or stator). An air gap exists between the stator and the
rotor. The rotor contains a winding supplied by a separate dc power source such as an exciter. This
energized rotor winding creates a radial magnetic field across the air gap. As the rotor turns, the magnetic
field cuts across the stator conductors and induces ac voltages in the stator winding. The rotor winding and
poles provide an electromagnetic interface that allows energy transfer between the prime mover (usually an
engine or turbine) and the secondary (the stator winding).
All salient-pole rotors consist of a straight shaft with poles affixed in some manner to the radial surface,
and an exciter armature or collector rings mounted on the connection end of the shaft. The construction of
the rotating exciter and its rotor-mounted parts is outside the scope of this guide.
F.1 Shaft
In large machines, the rotor shaft will typically be constructed from a forged and machined steel cylinder
with a considerable diameter, perhaps ranging from 15 cm to several meters. The diameter will vary from
end to end depending on the presence of flanges, bearing surfaces, and keyways and rings to which the
poles are attached. In all heat-treating and machining operations, the concentricity of the rotor radial
surfaces shall be maintained to ensure that the rotor will turn without vibration and distortion of the air gap
clearance. For similar reasons, special attention is required to protect the bearing surfaces from damage or
contamination.
F.2 Rotor construction
Salient-pole machines fall under three principal rotor categories: integral-pole, shaft, and shaft-and-spider.
Integral-pole rotors are found in high-speed (4-pole and 6-pole) units. In this construction, the poles, pole
tips and shaft are usually machined from a single forging to produce superior mechanical properties.
Integral poles do not have laminations, and they usually do not employ circuit elements such as shorting
segments or amortisseur bars (also known as damper windings). Insulated strip-wound copper conductors
(see 6.2.3 and F.3) are wound around each pole to form the turns, butting snugly against the underside of
the pole tip collar. Some Vendors prefer to construct this type of integral-pole rotors with separate pole tips
that are bolted into the pole body. Small slots and teeth are generally machined on the pole face of integral-
pole machines in such a way to simulate a kind of lamination stacking in order to reduce the pole face loss.
Shaft rotor constructions are used in high-speed units or units where very high inward-directed radial
acceleration type forces act on the poles. The poles are comprised of laminations stacked in the axial
direction of the rotor and held together under compression by endplates and rivets. These poles are wound
with insulated conductors in a similar fashion to that used in integral poles. They will have amortisseur
(damper) bars and shorting segments, which may or may not be connected pole-to-pole. Continuous
damper bar windings can handle unbalances to 10%. Discontinuous damper windings can handle only 5%
unbalanced stator phase currents. The body of the rotor (or shaft) is typically made from a machine forging
or constructed from steel plates or laminations. The poles can be attached to the rotor by means of dovetail,
T-shaped keys or bolts.
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IEEE Std 1665-2009
In some cases, on bolted poles, the bolts are removable from inside the rotor rim, to allow the possibility of
removing one pole without removing the rotor.
Shaft-and-spider rotors are typically found in low peripheral speed (< 200 rpm) generators. They have a
straight shaft to which a disc-shaped steel plate (the spider) is keyed, bolted, or shrunk-fit. The outside
diameter of the disc-shaped plate has an elongated ring attached to it, onto which the individual poles are
bolted. In some hydrogenerators, the spider and the rim can be made of cast steel. In large hydrogenerators,
the spider has radial arms, against which a laminated rim is piled to form a solid cylinder type component
about 0.5 m to 1.0 m deep radially. The poles are keyed onto this rim. The diameter of the spider is much
larger than that of the straight shaft that carries it. The individual laminated wound poles are in turn keyed
with dovetails or T-shaped keys, to the outer diameter of the rim. A fabricated hub with shaft extensions is
also possible. These poles are often equipped with amortisseur (damper) bars and shorting segments.
F.3 Rotor windings
The rotor windings of salient-pole rotors are generally made from copper strips brazed together or bent at
the corners and wound in a spiral fashion around the pole. These are often referred to as edge-bent
windings. The copper strips are insulated from the pole body itself by ground or main insulation, and each
strip will be insulated from its neighbor by turn insulation. The turns will appear to be stacked in a radial
direction relative to the shaft. Modern ground insulation is generally made of sheets of epoxy glass, and the
turn insulation is usually aramid paper or other similar electrical insulation material. Old rotors may be
insulated with papers or mica bonded with shellac. Asbestos insulation may also be present in these old
units. Newer designs do not employ asbestos.
The rotor poles usually have top collars, made of glass laminate or other rigid insulating material. These
provide mechanical stability to the conductors and turn insulation, protecting them from distortion and
abrasion by exerting a positive (inward-directed) radial pressure during operation of the machine. This is
particularly important during starting and stopping when large changes in these radial and angular
acceleration related forces occur. In small machines, the collars and ground insulation may be the same
component. In this case, an “L” shaped fiber piece is used.
In 4- or 6-pole machines, and on machines with long poles (typically over 2 m), blocks are wedged
between the conductors on adjacent poles and bolted into place to prevent movement of conductors in the
rotational direction. To prevent distortion, one manufacturer equips these blocks with pads of rigid resin-
bonded glass insulation to distribute the pressure between the conductors and themselves over a greater
area.
Wire-wound rotor windings are usually found in smaller machines. The wire is usually pre-insulated with
enamel, aramid paper, resin-bonded glass, or similar material. The wire is lapped around the pole in
successive layers. Each layer of insulated wire is stacked radially to the pole and insulated from its
neighbor with sheets of material that may be similar to that used in the construction of large generator rotor
windings. The bottommost layer of wire windings will also be insulated from the laminated pole in a
similar way. In some cases, the rotor poles will have been wet-wound with an epoxy, encapsulating the
whole winding to provide mechanical strength and electrical insulation between turns and conductor layers.
Before writing the specification for a rotor rewind, it may be helpful to remove one coil to determine the
degradation of the insulation.
When re-insulating a field pole, typically the copper coil is removed from the pole body itself, cleaned, and
re-insulated. It is important to note where the field coil is sitting with respect to the pole body before the re-
insulation takes place. Many designs are such that when the field pole is installed on the machine, the pole
body iron is in contact with the rim iron so that flux can flow between pole bodies when the amortisseur
circuit is active during a fault. This in turn allows the design ratio X"q / X"d to be near 1.0 so that so that
line current pulsations do not occur during fault conditions. The idea is that the rotor will appear as a
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IEEE Std 1665-2009
uniform subtransient reactance as opposed to the field poles having a different reactance than the gap
between poles. Therefore, a good fit of the amortisseur bars (ensuring they are not loose or damaged) and
the contact with the rim will keep this ratio nearer to 1.0. If the design accommodated contact between field
pole body to rotor rim, then this should be maintained.
F.4 Rotor electrical connections
Rotor windings generally have flexible insulated top and bottom series connections on each pole. In
hydrogenerators, the inter-pole connections are either flexible and uninsulated, or rigid and both braced and
insulated. The rotor leads connected to the collector rings are rigid copper bars, and could be insulated only
where necessary. They are generally mounted on the outside of the shaft. Alternatively, the rotor leads can
be made of insulated flexible cable, and passed through machined holes in the rotor shaft to the collector
rings, mounted at the connection end of the shaft.
If insulated connections are re-insulated, care should be taken to verify that there is no gap between the
rotor connection support and the connections.
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IEEE Std 1665-2009
Annex G
(informative)
Information typically supplied in a specification by Owner or Vendor
The specification for a generator rewind is a complex task. Unfortunately, it is not as simple as specifying a
power rating and also specifying the applicable IEEE new construction standard (IEEE Std C50.12 or IEEE
Std C50.13). This annex is included to assist Owners of generators in providing the necessary functional
requirements and data to the Vendor, so that the rewound generator will meet the long-term needs of the
Owner without over-specifying and adding unnecessary costs. The guidelines in this annex are divided into
two major categories: Those requirements typically specified by the Owner; and those requirements
typically supplied by the Vendor.
There are a number of parameters that should be supplied by the Owner that relate to site conditions and
parameters that relate to their local power system requirements. The Owner may also want to specify the
following:
⎯ The degree that the generator capability meets or exceeds their turbine capability
⎯ Whether to allow adjustments in power factor
⎯ The use of a peaking capability to meet maximum requirements
⎯ Additional margin to allow for future turbine upratings
In many cases, this is not a simple point of highest kilowatt output, but a kilowatt output available for a
given ambient-temperature condition where combustion turbines are part of the plant. This and other
information typically specified by the Owner is listed in Table G.1.
There are a number of design parameters that are normally developed by the generator rewind Vendor, after
the Vendor has been selected in response to the bid requirements. These parameters may or may not be
submitted as part of the bid response, (and if acceptable to the Owner) may become part of a separate
contractual agreement. But these parameters are usually not specified in the Owner’s request for bids. This
information is listed in Table G.2.
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IEEE Std 1665-2009
Table G.1—Information typically specified by the Owner

Parameter Typical values Notes
Rules for Statement(s) as to preferred criteria for There may or may not be a desire for the generator
matching turbine matching or coordinating with turbine to be the limiting component in the TG set or to
output output. allow for future up-ratings of the turbine.
Power rating, and Megawatts, volts, amps For new construction, voltage and current are
nominal voltage usually established by manufacturer. But for
rewinds, the Vendor shall match existing operating
parameters.
Secondary Typical choices: This is usually the cooling liquid at site that will be
coolant type a. 100% fresh water available to the generator coolers. Mineral or
b. 50/50 mixture of fresh water and biological content would also be important to know
glycol for cooler material selection and design.
c. 100% sea water
Secondary Typically 5 oC to 35 oC For ambient-following turbines it is important to

coolant know the dependence of secondary coolant
temperature temperature(s) upon the ambient temperature. For
non-ambient-following turbines it is usually
sufficient to know the maximum secondary cooling
water temperature that could occur during the year.
Temperature Number and location of resistance IEEE Std C50.13 does not require the manufacturer
detectors temperature detectors (RTDs) or to install embedded temperature detectors in the
thermocouples (TCs) stator slots of direct-cooled coils. Instead, it only
stipulates temperature detectors at the coolant
discharge. If the Owner wants temperature
detectors embedded in the stator slot, they should
be specified.
Altitude Usual range from 0 m to 1000 m. A higher A given air-cooled generator capability will
altitude can be specified. decrease with altitude.
Sound emissions A typical value is less than 95 dBA sound Sound is specified in new construction, but NOT in
pressure at one meter. rewinds. For rewinds, the Vendor is limited to
existing operating parameters.
Type of 3 000 lifetime total start capability for base It should be specified whether this is a base load
operational duty load units. unit or a peaking unit, or a frequently cycled unit.
10 000 lifetime total start capability for Any additional details regarding operational duty
peaking or frequently cycled units. could be useful to the Vendor to ensure that the
design is adequate.
(continued)
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IEEE Std 1665-2009
Table G.2 (continued)

Parameter Typical values Notes
Rated power Typical selection values are 0.80, 0.85, and Power factor is specified in new construction, but
factor 0.90. NOT in rewinds. For rewinds, the Vendor is
limited to existing operating parameters.
Short circuit ratio For turbo-generators, a typical range is 0.35 A typical value for a short circuit ratio is based on
(SCR) to 0.58. For hydrogenerators, the minimum steady state stability in the power system where the
is typically 0.8. generator is installed. SCR is specified in new
construction, but NOT in rewinds. For rewinds, the
Vendor is limited to existing operating parameters.
Recommended Owner should establish the scope of supply

site testing responsibility and requirements for site testing.
Special Owner should determine whether or not these tests

performance are required. Many Vendors recommend
testing performing this testing only when verifying a new
design or type of machine.
Quality standards ISO standards
Other Current transformers, cold air temperature Owner should furnish specifications and drawings
instrumentation detectors, fire extinguishing systems
Table G.3—Information typically supplied by the Vendor or repair firm

Parameter Typical Value Notes
Capability at Reactive capability curves at selected
reduced hydrogen reduced gas pressures.
pressure
Efficiency Vendor will specify which supplemental Where the turbine and generator are procured as a
losses are included when supplied and set, the generator losses are normally incorporated
provide reference temperatures for into the overall turbine-generator heat rate. In this
statement of I2R losses. A tolerance of case, stand-alone generator efficiency is not
±10% is common, for provided losses when typically guaranteed separately. Vendor may also
compared to test values. supply the supplementary losses, in addition to the
Joule losses. In the tender document, the Vendor
should notify the Owner if the 10% tolerance is
applicable to the measurement of the guaranteed
segregated generator losses
Phase sequence Sequence of timing of voltage peaks at It is usually good practice to specify this
main terminals. Two phase sequences are geometrically such as “left-center-right” as viewed
possible. Typically the existing phase from a position or to show on a drawing to ensure
sequence is maintained. clarity rather than using terminal numbering such
as “T1-T2-T3.”
Rated terminal For new construction, this is typically Depending upon MVA rating and the Vendor’s
voltage supplied by the Vendor. For rewinds the design philosophy, there are usually limited
Vendor has a limited voltage range, in order winding combinations available, thus limiting the
to match the station transformers. number of economic voltage selections.
Rated rotor Rotor voltage and current at rated and other Rotor voltage is specified by the Vendor in new
voltage and important conditions. construction, but NOT in rewinds. For rewinds, the
current Vendor is limited to existing operating parameters.
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IEEE Std 1665-2009
Annex H
(informative)
Typical preparations for a rewind specification
The following list of questions is intended to assist the Owner in formulating the myriad of decisions that
have to be made in preparation for the generator rewind. Many of the points will then be used to establish
the total job requirements to be covered by the rewind specifications.
H.1 General
1) Is an uprating of the unit desired?

2) Is the maintenance history available for review?
3) Is the generator instruction book available?
4) Has original manufacturer issued any modification bulletins that should be implemented in this
rewind?
5) What type of load cycles are expected on this unit in the future?
6) What are the key dates that will apply to this work?
a) Rotor specification completed ______
b) Stator coil and rewind details completed ______
c) Stator rewind specifications completed ______
d) Bidders pre-bid meeting date ______
e) Rotor rewind bid date ______
f) Stator coils and details bid date ______
g) Stator rewind bid date ______
h) Shipping date for stator coils and details ______
i) Unit planned outage date—start of outage return to service ______
j) Rotor ship date to factory ______
k) Rotor return date ______
7) Will an experience list from Bidders be required?
8) What other work will be accomplished during this outage?
9) Is drug testing required for Vendor’s on-site personnel?
10) In what form is final documentation to be supplied? (Electronic? Hard copy? Bound?)
11) Will there be a bonus/penalty clause?
12) Logistics
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IEEE Std 1665-2009
H.2 Stator rewind
1) What NEMA class insulation is desired?

2) What is the Owner’s preference for VPI system?
3) Will spare coils, or spare circular rings, or spare wedges be required?
4) Inquire about the type of copper used: oxygen free, high conductivity (OFHC), ETPC, or silver
bearing?
5) Are any life tests required for the new coils?
a) Quality breakdown
b) Voltage endurance
c) Cycling tests
6) What is the Owner’s preference for coils that fail factory tests? Can they be refurbished and reused
for this project?
7) Any restrictions on transpositions?
8) Any objections to connection caps (“end caps”—epoxy filled or air spacing)? (Any endcap overlap
requirements should probably be specified.)
9) Any preference for endwinding ties or lashings?
10) If the end winding support system is modified, will a “bump” test be performed to ensure there is
no natural resonant frequency between 105 Hz and 138 Hz. Ask the Bidder for a cost and time
adder for this test if required.
11) Will photos be taken of the winding at both ends before the coils are removed? This may help
answer any questions, later. In addition, rewind progression photos may also be a good idea and
could solve problems.
12) If the overhang is to be modified, will a factory mock-up be required to assure proper clearances
are achieved on site? This is particularly important for air-cooled generators since inadequate
endwinding clearances can lead to interphasal partial discharge activity.
13) Any preference for connections joining methods? (Soldering, brazing, etc.)
14) Tightness requirements?
a) Tests
b) Sizes
c) Section voids
d) Flatness
15) Will new parallel rings be required?
16) Will new parallel ring blocking be required?
17) What is condition of main lead bushings? Any test requirements?
18) What support will the rewind Vendor get from the plant?
19) What is availability of utilities for the Vendor?
a) Station service ac power?
b) Compressed air—kPa or psig?
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IEEE Std 1665-2009
c) Toilet facility?
d) Drinking water?
e) Telephone?
20) How is waste material disposed of?
21) Will there be a Contractor’s office location?
22) What other Vendor employee access limitations are there?
23) Will there be a lunch and change house location?
24) Are material safety data sheets required?
25) If so, where should they be submitted?
26) What is the current condition of stator core?
27) Will work be required on the stator bore rings?
28) What tests will be applied to establish the integrity of the core?
a) Full flux loop test with infrared scan?
b) (The Owner may want to establish in advance the maximum allowable hot spots and how they
are to be measured. This includes temperature readings with respect to background, ambient,
average, tooth-face to tooth-face, bottom of slot to bottom of slot, etc. This can all be included
in the specification.
c) Low energy core flux test?
d) Others?
29) Will the through-bolts and hardware require replacing?
30) How will core repairs be performed?
31) What type of stator wedge procedure is to be utilized?
32) Will the RTDs and board require replacing?
33) Who will own and dispose of old copper?
34) Will the generator be made available for Bidders to take measurements?
35) And if so, when?
36) What technical data is required with the bid?
a) Stator winding resistance?
b) Loss data?
c) Material samples?
d) Quality control procedures?
37) How will the new coils be packaged for shipping?
38) Will long term storage be required? If so, where?
39) Will any new spare coils be packaged for long term storage?
40) How will safety and environmental issues be handled?
41) What will be required to isolate and control the environment in the work area?
42) Will source inspections be required during manufacturing?
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IEEE Std 1665-2009
43) Will installation inspections be required? (The Owner’s engineer should make the final inspection
with the Bidder’s supervisor)
44) Progress reports?
45) Test reports?
46) What reports and calculation notes are required?
47) How will additional work be handled?
48) How will Bidder qualifications be handled?
49) Will test procedures be submitted in advance for the Owner’s engineer approval?
50) What will be the availability of the overhead crane and who will operate, and test?
51) Safety topics—Plant requirements, safety procedures, equipment lock out / tag out procedures,
clearances, etc.
H.3 Rotor rewind

1) Will new copper be required for the rewind?
2) Who will own the old copper?
3) Is replacement of the retainer rings required?
4) What is to be replaced on the axial and radial lead assembly?
5) What checks, tests, and inspections are to be made on the rotor body?
a) Rotor tooth test?
b) NDE inspection?
c) Rotor boresonic inspection?
d) Hardness tests?
6) Will the collector rings require replacing?
7) Will any modifications to the rotor slot teeth be required?
8) Will high-speed seasoning be required?
9) Will high-speed balancing be required?
10) Who will package and ship the rotor from plant site?
11) What technical data will be required with bid?
12) What technical data will be required from the successful Bidder?
13) What procedure will be used to qualify Bidders?
14) Will an experience list be required with the bid?
15) How will rotor be protected during shipping?
16) Are new slot wedges required?
17) Will source inspections or witness tests be required?
18) What test data will be required?
19) Will progress reports be required?
20) Transportation: Who will be responsible for transportation costs?
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IEEE Std 1665-2009
Annex I
(informative)
Typical stator rewind specification for turbo-generators
NOTE—This annex is informative only, and not part of IEEE Std 1665™. The annex contains a sample specification,
which includes some detailed repair protocols and/or some recommended chemicals. This specification is intended as
an illustration of detailed turbo-generator specification. (Hydro-generator stators are addressed in Annex K.) It is only
an example, intended for illustration. The requirements may or may not be appropriate for every generator. Some
Contractors may consider some of the requirements herein as an encroachment into their design. Furthermore the terms
may result in the Contractor taking exceptions to the specification, or it may increase the costs to the Owner. The
generator Owner should carefully consider all the terms, and not just adapt this as a “standard” template. If there is any
doubt concerning the appropriateness of a requirement in this specification, the Owner should consult with the
generator manufacturer, or a qualified generator consultant. This specification is not appropriate for water-cooled
windings.
I.1 Description of the project
The total scope of work of this project is a complete replacement of the stator winding of the turbo-
generator. The Contractor shall state any proposed deviations from this specification.
I.1.1 Definitions
Bidder: the companies requested to bid on this contract

Contractor: refers to the supplier manufacturing and/or installing the winding, and/or performing any
other work on the machine.
Engineer: refers to the engineer employed by or retained by “Your Company” and is responsible for this
specification.
Owner: Happy Valley Electric Company (a fictitious Owner name for illustration)
I.1.2 Standards for this project
The following standards are indispensable for the execution of this project. Unless otherwise specified, the
latest edition of the referenced standard applies.
IEEE Std 62.2, IEEE Guide for Diagnostic Field Testing of Electric Power Apparatus—Electrical
Machinery.
IEEE Std 67, IEEE Guide for Operation and Maintenance of Turbine Generators.
IEEE Std 95, IEEE Recommended Practice for Insulation Testing of AC Electric Machinery (2300 V and
IEEE Std 115, IEEE Guide: Test Procedures for Synchronous Machines.
IEEE Std 286, IEEE Recommended Practice for Measurement of Power-Factor Tip-Up of Electric
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IEEE Std 1665-2009
I.2 Machine data
Manufacturer: provide name

Type: give all pertinent information
Stator circuit configuration: wye or delta
Commercial date: month and year
Nameplate data: provide all data
NOTE—In this section, the Owner should specify the unit out-of-service date and the required return-to-service date.
The Owner should also provide any significant maintenance or operating information about the stator and rotor.
I.3 Owner’s responsibility (as required)
1) The generator shall be properly “tagged out” in preparation for the rewind. The hydrogen and
carbon dioxide piping (spool pieces) to the stator shall be removed and tagged.
2) The end brackets (end bells) will be removed. Internal baffles will be removed. The rotor will be
removed.
3) The work area will be cleared to provide easy access to the generator. A lay down area shall be
provided for the Contractor’s equipment and supplies. Turbine room configuration will be taken
into account.
4) Old bars shall be removed from the work area as soon as possible.
5) Be sure that a proper electrical power supply, a compressed air supply, phone service, and crane
usage is available. Lunchroom and restroom facilities should also be provided for Contractor.
I.4 Requirements
The materials to be supplied and the work scope to be completed by the successful Bidder are to include
but are not limited to the items listed below.
I.4.1 Materials
1) The stator windings are to consist of a complete set of top and bottom bars plus four spare top and
four spare bottom bars, and all necessary winding supplies. (The Owner should specify a sufficient
number of bars, or half coils, in order to replace a failed bottom bar.) The bars are to be insulated
with a full Class 155 (F) insulation system constructed with mica-based materials, bonded with
solvent-less thermosetting synthetic polyester or epoxy resin fully insulated, VPI processed, or
resin-rich hot pressing processed and cured. No polyester or other plastic films are permitted. The
successful Bidder shall provide details of all factory tests, the total insulation system, core slot
preparation, and the anti-corona protection system. Coils that fail factory tests may not be
refurbished and reused for this project. All bars, including rejected bars, shall be numbered and
tracked from conception through installation or disposal.
All new coils shall be subjected to a factory power factor tip-up test. (The Owner and Contractor
shall agree on voltage levels and acceptance criteria. [Ref. IEEE Std 286]
The spare bars should have universal leads to accommodate use as a phase or series bars. The spare
bars are to be packaged for long-term storage and priced separately.
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IEEE Std 1665-2009
The Bidder shall submit a detailed drawing of a stator bar cross section showing the build-up of
insulation and dimensions of the bar and slot. The copper cross section shall be equal to or greater
than the original. If slot space exists due to the use of new insulation systems, the copper cross
section should be increased rather than using slot fillers. The bid package shall also contain
drawings and specifications necessary for installation of the new winding. Spare bars, if they exist,
should be made available for inspection by the Bidders.
2) The stator bars shall have a copper cross section equal to or greater than the original design. The
ground wall insulation voltage stress shall be 50 V/mil (this calculation may include strand,
groundwall, and non-conductive armor tape). The slot portion shall have a Roebel-type
transposition of 360° [or equivalent to the original design], and be dimensioned for use with a side
ripple spring. As an option, quote a 540° Roebel transposition.
3) If existing connecting rings are reused, provide all new Class 155 (F) materials required to re-
insulate the rings, the endturn axial supports, and the connection ring supports. The stator bars shall
fit-up to the existing connection rings without major modifications.
4) If new connecting rings are supplied they shall be insulated with Class 155 (F) materials. Insulation
details shall be provided.
5) Provide shelf-life materials to block and tie the endturns and connection rings and insulate the
series connections, phase connections, and lower lead connections to the high voltage bushings.
Thermosetting materials are preferred, but air-dry materials may be quoted. Thermosetting
temperature and time requirements shall be provided.
6) Long shelf life materials should include shims, wedges, slot filler, slot RTDs, blocking, hardware
(non-magnetic bolts, washers, lockplates), insulation, side ripple springs, glass roving ties, dry
tapes, etc. necessary to permit complete installation of the new winding.
7) If soldered clips are used for series and phase connections, all solder materials and clips shall be
provided. A sketch of the clips shall also be supplied. If connections are to be brazed, all brazing
materials shall be provided including details of brazing tongs to be used.
8) New bottom bar support rings constructed from non-conductive materials (glass) are to be supplied.
9) Also include materials to provide for unrestricted axial expansion of the new winding in the
endturn area while providing end turn restraint from excessive movement during a short circuit
event. If new end winding supports are provided, complete support system details shall be included.
10) Provide a detailed and complete scope of supply.
11) Non-domestic suppliers shall include the Business Class airfare cost for three (3) round-trip visits
to the manufacturer’s facility by the Owner’s engineer.
I.4.2 Contractor’s scope of work
1) Contractor shall attend at least one (1) pre-outage rewind meeting at the plant or the Owner’s
office.
2) The Contractor shall provide physical protection for the turbine room floor and all scaffolding
required for the work.
NOTE—This is the Owner’s choice. In some cases the Owner provides the floor protection and scaffolding.
3) The Contractor shall provide a written procedure to protect the generator from foreign materials. A
tool and equipment “logging” system shall be used. Access to the stator frame shall be restricted
and limited at all times.
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IEEE Std 1665-2009
4) Remove the existing stator winding. The scrap windings remain the property of the Owner.
Extreme caution shall be used when removing coils. Depending on the regulations, the main crane
should not be used to extract the old stator bars or coils from the stator slots. Contractor shall repair
any core damage resulting from bar removal. If required, asbestos abatement requirements for
Contractor’s employees are the responsibility of the Contractor, and proof of certification shall be
provided.
NOTE—This annex is intended as an illustration of detailed generator rewind specification. Some Owners
may choose to have the Contractor dispose of the winding and credit back the salvage value to the Owner.
This is very advantageous if asbestos is in the winding.
5) If new connection rings are not provided, the original connection rings shall be removed and the
existing insulation stripped and the rings completely re-insulated with Class 155 (F) insulation. The
reinsulating method to be used shall be described.
6) All high-voltage bushing connections and leads shall be stripped and re-insulated (if necessary) for
rated voltage. The bushings shall be physically protected to prevent damage during the work. All
bolted connections shall be silver-plated.
7) The end winding and phase connection axial supports may be removed and the existing insulation
stripped and completely re-insulated with Class 155 (F) insulation. Describe the reinsulating
method to be used. Existing support bracket bolts may be reused. The bolts, nuts, washers, or bolt
holes shall be thoroughly cleaned.
8) Mylar® 23,24 or other plastic film materials are not to be used except in sacrifice applications; these
materials are to be removed.
9) Satisfactorily clean, vacuum, and prepare the core and slots for installation of the new winding.
Core slots shall be painted with a semi-conductive paint. (Note that some Contractors may not
normally to do this.)
10) The successful Bidder shall provide the equipment and perform a low energy non-destructive core
test to identify interlamination imperfections on each rewind. If a high energy core test (a loop test)
is determined necessary to evaluate the core, the Contractor will provide the required cable and test
equipment. A cost and time adder for a full core loop test should be provided. The necessary source
capacity for a loop test will be provided by the Contractor.
11) Install side ripple springs with the new coils.
12) Install, connect, and test new stator slot RTDs (or thermocouples) included with the winding
supplies. These shall be located where the original RTDs were located. As an option, twelve (12)
shall be provided; each circuit should have two RTDs equally spaced in the winding.
13) The series and phase connections may be mechanically clipped and soft soldered or brazed and
shall be insulated for rated machine voltage. An insulating boot may be offered as an option to
taping these connections; full details and material specifications should be provided for approval.
14) New non-conductive bottom bar support rings are to be utilized to replace the original support
rings.
15) Provide a complete description of the stator wedging method to be used. During the rewedging
process, the following rules shall be observed:
a) A wedge will be considered “tight” only when 60% or more of its length is tight.
b) No more than two adjacent wedges may be loose.
23
24
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IEEE Std 1665-2009
c) No more than four loose wedges are permitted in any one slot. A qualitative “tap” test may be
used to check tightness.
16) The end turn support system, at both ends of the core, should provide for unrestricted expansion of
the winding in the axial direction to avoid insulation damage from thermal stress. A description of
the method to be used shall be included. The endwinding blocking and tie pattern shall be clearly
identified. The Owner shall approve any significant deviation from the proposed or original pattern.
17) The endturns will be flooded with one (1) application of suitable epoxy. The resin shall be
approved by the Owner.
18) The Contractor is responsible for all testing. The Contractor shall specify all tests recommended
during the rewind process. The tests will be reviewed and approved by the Owner. The completed
new winding shall successfully pass a final high potential test at (2E+1) kV, 60 Hz, AC for one (1)
minute (an equivalent dc test is not acceptable). The Owner will witness the acceptance test. The
AC high-potential withstand test shall not be performed until the winding passes a 5 kV DC
polarization index test and as approved by the Owner.
NOTE—In the above paragraph, the Owner would normally specify 50 Hz or 60 Hz, whichever is
applicable. Also the Owner may be willing to accept “an equivalent dc test.” *
19) Natural frequencies and vibration – The vibration characteristics of the stator core and frame should
not be altered in any detrimental way by the installation of the new winding and support structures.
The vibration characteristics of the new stator winding and its support structure should be such that
there are no resonant frequencies near the once (60 Hz) and twice (120 Hz) per revolution natural
frequencies of the electrical system. An exclusion zone around these natural frequencies is
required. At least +/-10 Hz on either side is a minimum, but preferably +/-20 Hz is desirable for the
2, 4, 6, and 8 node modes. The further away from the natural electrical frequencies, the better.
To ensure the above, a bump test to determine the natural resonant frequency of the various
endwinding components will be done. This will identify the predominant frequencies on the
various components tested. In addition to the bump testing, a modal analysis will be done to verify
there are no resonant frequencies in the 2, 4, 6, and 8 node modes in the frequency exclusion range.
The testing should be done to determine the fundamental resonant frequency and associated
response values of the following components:
a) Stator endwindings and supports, on both ends of the machine
b) Stator endwinding series and parallel phase connectors and circuit ring bus
c) Stator terminals and supports
Test data should be taken in both the radial and tangential directions at each test location. Data
related to the test locations, which exceeds acceptable criteria (agreed to by the Contractor and the
Owner), shall be analyzed to determine whether additional support is required. Additional support
can be added to the end windings by means of blocking and tying the series loops or phase
connections. Loops and connections requiring blocking and tying will be re-tested to confirm that
the additional support is sufficient.
* NOTE—This annex is intended as an illustration of detailed generator rewind specification. The requirements may
or may not be appropriate for every generator. The generator Owner should carefully consider all the terms, and not
just adapt this as a “standard” template. If there is any doubt concerning the appropriateness of a requirement herein,
the Owner should consult with the generator manufacturer, or a qualified generator consultant.
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IEEE Std 1665-2009
Should additional bump testing and modal analysis show that there are still natural frequencies in
the exclusion range, a re-assessment will be done by the Contractor and the natural frequencies
eliminated from the exclusion range according to agreed upon criteria between the Contractor and
the Owner.
20) Itemize, in the proposal, individual rates, expenses, and work schedule (shifts/day, hours/shift,
days/week, and workers/shift).
21) Contractor shall thoroughly vacuum and clean with a solvent the stator frame housing after the coil
removal and before installing new coils. Just before the final high potential test, the stator frame
housing shall be thoroughly cleaned and vacuumed.
22) The Contractor should provide, if requested by the Owner, a study report (mechanical, thermal,
electromagnetic studies, etc.) verifying that the new stator meets the Owner’s requirements.
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IEEE Std 1665-2009
Annex J
(informative)
Typical rotor rewind specification for turbo-generators
an illustration of detailed turbo-generator rotor specification. (Hydro-generator rotors are addressed in Annex L.) The
requirements may or may not be appropriate for every generator. Some Contractors may consider some of the
requirements herein as an encroachment into their design. Furthermore, the terms may result in the Contractor taking
exceptions to the specification, or it may increase the costs to the Owner. The generator Owner should carefully
consider all the terms, and not just adapt this as a “standard” template. If there is any doubt concerning the
appropriateness of a requirement in this specification, the Owner should consult with the generator manufacturer, or a
qualified generator consultant.
J.1 Description of the project
The total scope of work of this project is a complete disassembly of the generator rotor, a complete
inspection of the rotor body and retaining rings, which includes an ultrasonic bore exam, and the
replacement of rotor components as covered in this specification.
J.1.1 Machine data
The following is the complete nameplate information:
Manufacturer: provide name
Type: give all pertinent information
Stator circuit configuration: wye or delta
Commercial date: month and year
Nameplate data: provide all data
J.1.2 Schedules and dates
The following key dates will apply to this work:
Bid due date _________
Contract award date _________
Ship date winding material _________
Unit shut down date _________
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IEEE Std 1665-2009
Rotor ship date _________
Rotor return date _________
Return to service date _________
J.1.3 Definitions

Contractor: the company who is successful Bidder of this contract
Engineer: the Manager of Engineering of the Sunset Power Station of the Happy Valley Electric
Company, or any person or firm which said Manager of Engineering shall designate for that
purpose.
Subcontractor: any company or individual hired by the Contractor to perform any portion of the
Contractor’s scope of work.
ET: eddy-current testing
MPT: a non-destructive test utilizing magnetic particles or penetrants
NDE: a non-destructive examination or tests such as ultrasonic, magnetic penetrant, dye penetrant, etc.
PT: a non-destructive test utilizing dye penetrants
UT: an ultrasonic test
*
J.1.4 Standards for this project
Machinery.
IEEE Std 67, IEEE Guide for Operation and Maintenance of Turbine Generators.
IEEE Std 115, IEEE Guide: Test Procedures for Synchronous Machines.
IEEE Std 286, IEEE Recommended Practice for Measurement of Power-Factor Tip-Up of Electrical
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IEEE Std 1665-2009
J.2 Scope of work and supplies
J.2.1 Shipment of rotor
The rotor rewind Contractor shall be responsible for the supply of all protective covering, shipping skid,
and the arrangement of transportation from the plant site to the Contractor’s facility.
The rotor shall be transported in 100% sealed, moisture-protected, full-length plastic container bag that has
been purged and pressurized with dry nitrogen, and the shaft journal coated with rust inhibited material and
wrapped.
During shipment the rotor body shall be supported on one of the pole faces at three locations equally
spaced within the coil retainer rings. While on the shop floor the rotor shall be supported on “V” blocks at
the protected inboard seal fits or journals.
The dimensions and weight of the rotor are as follows:
Weight ______
Diameter of body ______
Length of body ______
Total length ______
NOTE—At no time shall the rotor be supported on the retaining rings.
*
J.2.2 Checks and tests
At receipt of the rotor at the Contractor’s facility and before any disassembly of the rotor components, the
following checks and tests shall be performed.
1) With the rotor in the lathe, make an eight-point concentricity check at the following locations:
Rotor body ______
Retainer rings ______
Coupling ______
Journals ______
Seal fits ______
Blower hubs ______
Collector rings ______
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IEEE Std 1665-2009
2) Measure and record the insulation resistance to ground using 1,000 V dc, and the winding
impedance using 200 V ac.
J.2.3 Disassembly
1) All components of the rotor requiring heat to remove shall be heated with induction heating
equipment only.
2) Heat and pull the coupling.
3) Disassemble the aluminum blower segments; heat and remove the blower hubs (if applicable).
4) Remove the end plates from the retainer ring sub-assembly; heat and remove the retainer rings from
the rotor body.
5) Remove the end plugs from each end of the shaft and remove the four radial conductors, the axial
conductors and insulating tube, the collector leads, and the shaft filler bar.
6) Remove the two radial lead conductor wedges and keepers, and all the slot wedges. Clean and
visually inspect the wedges for mechanical damage. Any deformed wedges shall be replaced with
new wedges.
7) Remove the two radial lead conductors and cleats from the exciter end. Carefully remove the rotor
coils in a manner that will maintain their original shape and size.
J.2.4 NDE inspections
1) Prepare the rotor bore for a boresonic investigation and inspect the bore for defects, rust cleanness,
etc. Ream the rotor bore to meet the boresonic inspection requirements. Do not ream or disturb the
bore at the end plug gas tight fit. If any metal is removed from this area, new bore plugs will be
required.
2) Cover the end of the shaft bore, the bearing journals, the collector, and the seal fits with protective
covering and glass-blast clean the stripped rotor body.
3) Perform NDE inspections on the rotor and rotor components as follows:
a) Ultrasonic test the blower hubs, coupling, retaining rings and shaft extensions. Perform a
boresonic test of the rotor body.
b) Magnetic particle test the retaining rings, blower keeper rings, collector rings, rotor bore and
rotor slots for vent duct cracking.
c) Liquid penetrant test the blower blades, aluminum slot wedges, aluminum cleats, collector
rings, radial lead conductor wedges, and the radial conductors after the insulation has been
removed.
d) Eddy current test the retainer and the rotor body for tooth top cracking.
e) Rockwell hardness test is to be made on each of the retaining rings.
4) The results of all the above tests along with mechanical checks and tests shall be reported to Owner
before proceeding with the rotor rewind.
J.2.5 Reassembly preparations
1) Remove all the insulation from the rotor coil and clean the copper in preparation for reuse. Flatten
and reform and adjust the length and width of each coil to its original dimension as required.
Replace the two pole cross-overs with new laminated flexible type omega-shaped sections.
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IEEE Std 1665-2009
2) The cleaning of the copper rotor bars may be accomplished by blasting the copper surfaces with
crushed peach pits. During cleaning, care shall be taken to avoid any reduction in the cross
sectional dimension greater than 0.05 mm (.002 inch).
3) As an alternate to cleaning and reusing the existing copper, a separate price to supply new copper
for the winding will be submitted. The new copper shall be oxygen free, high conductivity (OFHC)
silver bearing, 0.62 g/kg (20 oz/ton) copper alloy type CDA 107 (Rockwell “F” scale 60–70 half-
hard).
4) Remove the original insulation from the radial conductors, clean and inspect for damage, and re-
insulate with a glass/epoxy composite tape. After the insulation is applied and cured, perform an air
pressure test of 690 kPa (100 psi) for leakage between the insulation and the conductor.
5) Inspect the end of the shaft plug fits and the shaft plugs for compliance with surface requirements
for a gas tight fit, and measure the dimensions with micrometers for the proper fit.
6) Alter the bottom steel coil support strips and the bottom of the slots at the length center line to form
a positive locking provision consisting of a washer welded to the bottom of the steel strip center
and a counter bore in the bottom of the rotor slots. Remove the bent corners on the original strips
and grind smooth.
7) Alter the cleats used to clamp the radial lead conductor to the rotor body end face by removing the
radial bolt holes, and replace them with a suitable steel strap spanning the conductor slot.
8) Alter the generator coupling and shaft to receive round coupling keys on reassembly.
J.2.6 Special rotor requirements
(if applicable) …
1) Replace 18-5 retaining rings with new 18-18 retaining rings

2) With the conductors removed from the rotor slot, conduct the short-ring or long-ring modification
on the rotor forging.
*
J.2.7 Reassembly of components
1) Re-insulate the refurbished rotor coils with glass epoxy NEMA grade G-11 insulation cemented to
flat sides of the bar.
2) Replace the original shellac-mica slot cells with continuous length molded cells.
3) Replace the original phenolic end-turn blocking with glass epoxy NEMA grade G-11 blocking.
4) The new retaining ring liners shall be NEMA grade G-11 material with a “non-stick”
fluoropolymer resin coating (such as DuPont™ 25 Teflon® 26,27 ) on the inner bore surface.
25
DuPont™ is a trademark of E. I. du Pont de Nemours and Company.
26
Teflon® is a registered trademark of E. I. du Pont de Nemours and Company.
27
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IEEE Std 1665-2009
5) After the rotor winding and wedging is completed, all of the components removed are to be
reassembled using induction heating equipment, and the rotor placed in the lathe for the final eight
point concentricity check.
6) During the final lathe concentricity check the journals and hydrogen seals fit area shall be
machined if required, and/or polished and all finished dimensions included on the final report.
J.2.8 Final electrical and mechanical tests
1) The following electrical tests are to be made on the completed rotor:

a) Insulation resistance and polarization index at 1000 V dc for ten minutes.
b) High potential test for one minute at 10 × rotor voltage.
c) Static impedance and pole balance impedance at 200 V ac.
d) Dynamic impedance test at 3600 rpm and 200 V ac at room temperature and at elevated
operating temperature of 125 °C.
2) The completed rotor will be given the following mechanical tests:
a) Dynamic balancing of the rotor at cold and hot temperatures up to 3600 rpm. The maximum
allowable vibration amplitude will be ______ mm peak-to-peak at 3600 rpm, and _____ mm
peak-to-peak at the critical.
b) Dynamic balance check of the rotor at 10% overspeed.
c) Dry nitrogen pressure test of 690 kPa (100 psig) of the axial leads and the shaft end plugs.
d) After dynamic balancing, a flux probe test shall be performed to verify that there are no
shorted turns.
J.2.9 Return shipment
The return shipment of the rotor back to the plant site will be as stipulated in J.2.1 of this specification.
J.3 Supplemental work conditions
1) If any additional work on the rotor becomes necessary that is not covered under the base scope of
this contract, the Contractor will notify Owner immediately with a description of the work to be
performed, a cost adder to perform the work, and a revised schedule to complete all work on the
rotor. No additional or extra work is to be performed until authorization is received from Owner.
2) All work performed by the Contractor is subject to inspection by Owner at any time. These source
inspections will be performed by the Engineer or a designated representative.
3) Any hold points for inspections will be established after a review of the Contractor’s schedule as
required in J.5.2. Owner shall be notified three days prior to such hold points being reached and
shall have the option to inspect or not inspect. The intents of the inspections are not to delay the
progress of the work, but to verify the quality and completeness of work being performed.
4) Owner will wish to witness the following final tests:
a) Rotor winding megger test
b) Dielectric absorption test
c) Winding impedance and pole balance test
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IEEE Std 1665-2009
d) Winding resistance measurement

e) Final high potential test
f) Overspeed test
5) The rotor rewind shall take place in a clean environment, free from conducting material
contamination.
J.4 Job progress
1) A preliminary project schedule, including activities, shifts, and duration, shall be developed by the
Bidder and submitted with the bid. A final project shall be submitted by the Contractor four weeks
prior to the start of work.
2) At a minimum the Contractor will submit to the Engineer weekly progress report on the work
performed and will update the project schedules with these reports. The Engineer has the right to
request more frequent updates whenever deemed necessary.
J.5 Deliverables
J.5.1 Deliverables with the bid proposal
1) A lump sum price to perform the total scope of work as covered in these specifications utilizing the
copper from the present winding, but replacing all other winding components as required by the
specifications
2) A lump sum price to perform the total scope of work as covered in these specification utilizing all
new copper
3) A price addition and a delivery schedule if replacement of both retaining rings is required
4) A cost breakout for the following items:
a) Price to perform the rotor bore inspection and engineering evaluation of the results
b) Cost credit for the existing copper if the rotor is wound using new cooper
c) Transportation, including shipping skid, protective shipping bag, and insurance. The rotor is
to be insured for $_______
5) A preliminary project schedule, including activities, shifts, and the duration of the work
6) The location of the shop where the work is to be performed
7) A list of any additional work that the Bidder deems as necessary and the price to perform such
work
8) A list of Subcontractors to be utilized
9) A list of exceptions and/or clarification to the contract
10) A list of generator rotors of this size and larger that the Contractor has rewound in the past five
years
11) A description of the Contractor’s quality assurance program
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IEEE Std 1665-2009
*
J.5.2 Deliverables after contract award
1) A final project schedule, submitted no later than four weeks prior to the start of the job
2) At a minimum, weekly updates on the work progress and schedule revision
3) A list of the standard inspections and tests that will be performed by the Contractor during the
rewinding of the rotor
4) A written report documenting the following:
a) Condition of the rotor when received
b) Measurements taken
c) Results of rotor tooth check
d) All NDE findings and resolutions, including photos and/or sketches
e) Preliminary rotor bore inspection results indications and re-inspection within two days after
the first inspection results are obtained
f) Final rotor bore inspection results, including engineering evaluation and a recommendation
for re-inspection frequency, within 15 days of completed inspection
J.6 Commercial
All Commercial terms and conditions under this contract shall be in accordance with Owner terms and
conditions. A copy of these terms and conditions will be included in the formal request for quotations.
An amount of 10% of the lump sum price will be retained until the rotor has been returned to satisfactory
service and the final written report has been received and accepted. Extra work invoices for additional work
as approved by Owner are to be submitted for payment at the time the work is completed.
J.7 Attachments
⎯ General assembly – collector end

⎯ Owner request for quotation and terms and conditions under a separate cover
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IEEE Std 1665-2009
Annex K
(informative)
Typical stator rewind specification for hydrogenerator
an illustration of a detailed hydrogenerator stator specification. (Turbo-generator stators are addressed in Annex I.) It is
only an example, intended for illustration. The requirements may or may not be appropriate for every generator. Some
generator manufacturer, or a qualified generator consultant.
K.1 Description of the project
The total scope of work of this project is a complete replacement of the stator winding of the
hydrogenerator. The Contractor shall state any proposed deviations from this specification.
K.1.1 Definitions

Contractor: Refers to the supplier manufacturing and/or installing the winding, and/or performing any
Engineer: Refers to the engineer employed by or retained by the Owner and is responsible for this
specification.
K.1.2 Standards for this project
Machinery.
IEEE 286, IEEE Recommended Practice for the Measurement of Power-Factor Tip-Up of Electrical
IEEE Std 492™, IEEE Guide for Operation and Maintenance of Hydro-Generators. [B9] 28
IEEE Std 522, IEEE Guide for Testing Turn Insulation of Form-Wound Stator Coils for Alternating-
Current Rotating Electric Machines.
IEEE Std 1043, IEEE Recommended Practice for Voltage-Endurance Testing of Form-Wound Bars and
Coils.
28
The numbers in brackets correspond to those of the bibliography in Annex A.
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IEEE Std 1665-2009
IEEE Std 1310, IEEE Recommended Practice for Thermal Cycle Testing of Form-Wound Stator Bars and
Coils for Large Generators.
IEEE Std 1553, IEEE Standard for Voltage-Endurance Testing of Form-Wound Coils and Bars for
Hydrogenerators.
*
K.1.3 Machine information
K.1.3.1 General machine data
(The Owner would complete these tables with information from their unit.)
Operating designation
Manufacturer
Serial number
Nameplate rating MVA
Maximum continuous rating MVA
Power factor
Terminal voltage V
Current A
Phases
Frequency Hz
Number of poles
Speed RPM
Orientation—vertical or horizontal
Direction of rotation CW or CCW (or both)
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IEEE Std 1665-2009
K.1.3.2 Stator data
Continuous pile, 2 section, 4 section

Bore diameter
Gross length
Air ducts (# of ducts, and dimension)
Core packets (# of packets, and dimension)
Number of slots
Skew in core
Slot width
Slot wedge width
Total slot depth
Total coil depth
Slot pitch
K.1.3.3 Winding configuration
Lap or wave
Number of coils
Turns/coil
Throw
Coils pitch
Coil grouping
Connection
Number of coils required
Number of spare coils required
RTD—number required (48 min)
Thermocouples—number required (48 min)
Termination box required
K.1.3.4 Machine history
Here the Owner would describe the machine’s history for the Bidder.
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IEEE Std 1665-2009
K.2 General requirements*
K.2.1 Core preparation
Before the core is cleaned, the core should be inspected for signs of fretting dust, or damage. The core
should be loop-tested to identify any hot spots. Any hot spots shall be remediated during the rewind. These
areas should be looked at more closely when the core has been cleaned. Refer to the rest of this standard for
direction on diagnosing and repairing problems.
The core should be cleaned using a corn cob blast, dry ice blast, or a dry ice blast with solvent, as
appropriate. The solvent shall be approved by the Owner. Care shall be taken when blasting, to ensure
damage does not occur to the core from the blasting media. When cleaning is completed, all the corn blast
(if used) and other debris shall be removed from the generator and a visual inspection completed for any
core imperfections. Laminations that have minor bends or dents shall be straightened and fixed into place
with wicking epoxy to prevent vibration-related failure. Any smearing of the laminations shall be repaired
so that laminar separation is achieved before the winding is installed.
The core bolts should be checked for torque per the original OEM design. The slots may be painted using
an air sprayer with semi conducting paint. This will help in preventing rust build up in the slot should a
water deluge take place. This also improves the surface contact resistance between the coil, side packing,
and core.
K.2.2 Winding and associated assemblies
1) The stator winding system shall be a thermosetting type incorporating a very well consolidated
Class 155 epoxy insulation system throughout as defined in IEEE Std C50.12 or latest revision
thereof.
2) This winding, together with subsystems such as wedging, packing, etc., shall be suitably designed
to withstand the forces encountered under normal operating and electrical fault conditions.
3) The Contractor shall provide strand repositioning such as Roebeling or inverted turns to control
circulating currents.
4) Mylar® 29,31-backed tapes of any kind are not acceptable but may be used as sacrificial layers
during the manufacturing process.
5) Strand insulation shall be Class 155 material. Dacron® 30,31 glass and/or enamel finishes are
acceptable. All strands shall be individually insulated.
6) The copper cross-section shall be maximized after considering installation tolerances and the
required insulation build.
7) Ground-wall insulation shall be Class 155 material. The voltage stress shall not exceed 65 V/mil.
The build shall also be capable of withstanding all high potential tests as described in this
specification.
29
30
31
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IEEE Std 1665-2009
8) On multi-turn coils, dedicated turn insulation is required and shall be Class 155 material. Turn
insulation is to be of adequate build for the factory turn-to-turn voltage test.
9) Semi-conducting tape or paint shall be applied to the slot portion of each coil.
10) Voltage grading tape or paint shall be applied to the coil arms over an appropriate distance beyond
the semi-conducting tape or paint. The interface between the semi-con and grading layers shall be
such that this interface does not deteriorate with time due to electrical stress.
11) The slot portion shall be straight, clean, free of defects and indentations (scarring, etc.), and have
uniform finish. Dimensions to allow a minimum 0.9 mm (0.035 in.) total slot side clearance if hard
side packing is used.
12) Any coil can be installed in any slot.
13) All coils, other than the spares, shall have their leads factory prepared and ready for site
connecting. This lead preparation includes forming, slugging, and trimming of strand groups. All
bare copper is to be free of varnish and resin. Bleeding of the copper before brazing at site will
produce the best connection.
14) Spare coil leads shall be sufficiently long to allow site forming to suit, regardless of coil position
within the winding.
15) If the winding is designed with separate pole jumpers, the Contractor shall supply one complete set
of stranded pole jumpers plus sufficient spares. Bare copper at the ends of the jumper shall be free
of resin and varnish and factory=formed. The insulation build shall be not greater than 65 V/mil.
K.2.3 Coil support structure
1) The coils shall be adequately supported and braced to a non-magnetic ring in order to prevent
movement within the slots and to withstand all stresses developed under operation, under electrical
fault conditions, and under the worst out-of-phase synchronization. This non-magnetic ring shall be
insulated with Class 155 material.
2) The ring shall be adequately supported either directly from the stator frame ends or from the core
end finger plates. The ring shall also be grounded to the stator frame using a separate conductor.
K.2.4 Circuit rings, neutral and main bus and associated assemblies
1) If practical, the circuit rings, main bus, and neutral bus may be re-used and re-insulated at site.
2) New circuit ring segments shall be of solid copper and shall be pre-formed and factory-insulated
with Class 155 materials except for the ends to be joined. The rings may be circular or flat.
3) Insulation shall be applied in order not to exceed 65 volts/mil of electrical stress.
4) New circuit rings shall be free of warping when delivered to site. Warped ring segments will be
replaced by the Contractor and at their expense. Circuit ring supports are to be provided for
mounting to the core-end finger plates or stator frame using insulating threaded rod and
accompanying hardware. Support blocks shall be NEMA grade GP03 or equivalent, free of sharp
edges, and bevelled where the circuit ring mates with the support block to ensure no sharp edges
damage the insulation. The support blocks shall also be pre-drilled to accept the threaded rod or
pre-drilled to accept angle iron support at the bottom of the block. The lashing system shall be
designed to minimize thermal expansion stresses to avoid damaging the circuit ring insulation. A
spare length of circuit ring may be ordered at this time and stored in the powerhouse in case it is
needed in the future. These circuit rings are not always available in a timely fashion.
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IEEE Std 1665-2009
5) The neutral and main output bus leads shall be insulated so the electrical stress does not exceed
65 V/mil.
K.2.5 Side packing system
The side packing system shall ensure a positive force on the coils towards the slot side for the life of the
winding. The side packing system can incorporate a follow-up mechanism such as a ripple spring, or the
flat style of packing may also be used. This will depend on the winding design and rating of the machine.
The OEM should be consulted for the optimum arrangement.
K.2.6 Wedge system
The wedge system shall ensure a positive radial force on the coils in the slots. The preferred method would
involve a system that maximizes the follow-up in the radial direction during the life of the winding. The
wedge system should also provide a positive locking system to prevent wedge and filler migration during
operation. The wedges may be of Class 130 material. The Contractor shall submit the wedge design
information with the proposal.
K.3 Material requirements *
1) Sufficient spare coils shall be supplied to allow replacement of coils in the event of a coil failure.
The Contractor shall state the number of spare coils being supplied in the proposal. The preferred
method is to replace the entire multi-turn coil and not to splice in a half coil in the event of a failure
during installation. Normally, enough coils to do one pre-lift should be sufficient for spares. For a
Roebel winding, 6% top coils and 3% bottom coils would be sufficient.
2) One set of RTDs or copper constantan thermocouples (minimum per the latest version of ANSI
C50.12).
3) Each thermocouple (or RTD) shall be suitably mounted in a recessed cavity in a middle packer that
sits between two coils in the slot. The entire assembly shall be treated with semi-conducting
compound, including the leads.
4) One set of slot wedges complete with sufficient quantities of depth packing, and any other
installation materials is required. A sufficient quantity of wedges shall be provided including a 5%
breakage allowance.
5) One set of bottom strips, middle separators, and wedging strips that are sufficiently long to cover
the required slot length in one piece (multiple piece assemblies are not acceptable). Quantities
should allow for some breakage. Bottom strip and middle separator materials shall be semi-
conducting. The middle separator shall not be wider than the coil and at least 2.3 mm (0.090 in)
thick.
6) One complete set of side packing allowing for some breakage. The side packing material shall be
semi-conducting. The pre-lift side packing shall be one piece from front to back—two piece side
packing is not acceptable.
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IEEE Std 1665-2009
7) One set Dacron® 32,33 felt sufficient to properly block the specified winding in the end head area.
8) Fibreglass roving, sufficient to properly bind and secure the specified winding.
9) Epoxy resin and hardener as required to properly install the specified winding.
10) Sufficient cleaning solvent (for cleaning tools and general epoxy cleanup) for the size of the
winding being installed. Check with the local laws on what types of solvents can be used.
11) Sufficient silver brazing ribbon, rod and mica tape for all copper joints.
12) Sufficient welding rod to join coil-support ring segments.
13) Any other material necessary for the complete rewind of the stator winding.
14) Extra material (non perishable) is also recommended as it can be stored long term at the station in
case of a failure. Sufficient material to install the number of spare coils ordered would be adequate.
K.4 Required information
1) Before manufacturing begins, the Contractor shall submit a dimension drawing of proposed coil
configuration.
2) Calculation notes on the wedging system and stator winding mechanical capability during fault or
abnormal operating conditions.
3) The Contractor shall submit a dimensioned drawing of proposed coil cross-section (with expected
copper loss in kW) located within a slot and showing stranding, turn and ground-wall insulation,
slot wedge, side and depth packing.
4) Describe all proposed packing, wedging, blocking, tying, and other materials.
5) A drawing detailing the wedge assembly, including installation instructions, and deflection
tolerances on the various components to be measured.
6) A drawing detailing the circuit ring assembly and finished tolerances of the winding on the top and
bottom end of the machine.
7) A drawing of the main lead arrangement with connection details to the existing bus bar or power
cables.
8) A drawing of the CT arrangement.
9) A drawing of the neutral leads, neutral cable connection, and the CT arrangement.
10) One complete set of reproducible drawings in electronic form.
11) All drawings are subject to the Engineer’s approval before any manufacturing begins.
12) The Contractor shall provide the V/mil for the proposed design
32
33
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IEEE Std 1665-2009
K.5 Tests
K.5.1 High potential *
1) Windings shall be able to withstand high potential tests with ac voltage, 60 Hz, or dc voltages
(whichever is applicable) as described below.
2) Windings will be required to withstand the final installed and connected acceptance high potential
test of (V high potential = 2 × rms line to line voltage + 1000 V, 60 Hz for one minute).
3) All pre-lift coils shall withstand a V high potential × 1.22, 60 Hz test for one minute.
4) All coils installed and side packed during a work shift or similar period shall withstand a test of
(V high potential × 1.22, 60 Hz test for one minute).
5) Subsequent to passing the pre-lift and installed and side packed high potential tests, all coils
wedged and interconnected during a work shift or similar period shall withstand a one minute test
at (V high potential × 1.15, 60 Hz).
6) 60 Hz test voltages are multiplied by 1.7 when converting to equivalent dc high potential test
voltages.
K.5.2 Voltage endurance test
Two stator coils or four stator bars may be chosen by the Engineer at random, during production and/or
prototype design for voltage endurance testing. The test procedure shall follow IEEE Std 1043 and the
acceptance criteria shall be as described in IEEE Std 1553.
K.5.3 Tip-up
All coils are to be factory power-factor tested in accordance with the latest revision of IEEE Std 286. Each
coil is to be marked (on the manufacturing tag) with its tip-up value.
K.5.4 Thermal cycling test
Five stator bars or coils may be chosen by the Engineer at random during production and/or prototype
design for thermal cycle testing. The test procedure shall follow IEEE Std 1310. The test can be performed
by a manufacturer or an independent test laboratory.
K.5.5 Delamination
A check for delaminated coils shall be performed at the factory on every coil off the assembly line. This
delamination check shall be documented and results including coil number and verification of testing. A
description of the tool used to check for delamination and how this test will be administered shall also be
submitted with the proposal.
* NOTE—This annex is intended as an illustration of detailed generator rewind specification. In subclause K.5.1, the
Owner would specify 50 Hz or 60 Hz, whichever is applicable. Also the Owner may or may not be willing to accept
“an equivalent dc test.” The requirements may or may not be appropriate for every generator. The generator Owner
should carefully consider all the terms, and not just adapt this as a “standard” template. If there is any doubt concerning
the appropriateness of a requirement herein, the Owner should consult with the generator manufacturer, or a qualified
generator consultant.
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IEEE Std 1665-2009
K.6 Warranty
The Contractor shall state the terms and conditions of the warranty for the winding.
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IEEE Std 1665-2009
Annex L
(informative)
Typical rotor rewind specification for hydrogenerators
an illustration of a detailed hydrogenerator rotor specification. (Turbo-generator rotors are addressed in Annex J.) It is
only an example, intended for illustration. The requirements may or may not be appropriate for every generator. Some
generator manufacturer, or a qualified generator consultant.
L.1 Description of the project
This specification describes the requirements for cleaning and re-insulation of one (1) set of rotor coils.
Coil insulating collars, pole body insulation, as well as connection materials will also be required. The
Contractor shall state any proposed deviations from this specification.
L.1.1 Definitions

Contractor: Refers to the supplier manufacturing and/or installing the winding, and/or performing any
Engineer: Refers to the engineer employed by or retained by the Owner and is responsible for this
specification.
L.1.2 Standards for this project
Machinery.
IEEE Std 115, IEEE Guide: Test Procedure for Synchronous Machines.
IEEE Std 286, IEEE Recommended Practice for Measurement of Power-Factor Tip-Up of Electrical
IEEE Std 492, IEEE Guide for Operation and Maintenance of Hydro-Generators. [B9]
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IEEE Std 1665-2009
L.1.3 Machine Information *
L.1.3.1 General machine data
(The Owner would complete these tables with information from their unit.)
Station
Manufacturer
Nameplate rating
Maximum continuous rating
Power factor
Terminal voltage kV
Stator current A
Phases
Frequency Hz
Number of poles
Speed RPM
Runaway speed RPM
Orientation—vertical or horizontal
Direction of rotation
Turns per pole
Rotor guarantee temp rise ºC
Maximum rotor current A
L.1.3.2 Machine history
Here the Owner would describe the machine’s history for the Bidder.
L.2 Rotor rim/spider cleaning
Since the field poles have been removed, this is an ideal time to clean the rest of the spider and rim
assembly. Corn cob blast and or dry ice blast work well. It is not recommended to install newly rewound
poles onto a dirty rotor assembly. Check coil springs for damage and clean for reuse.
L.2.1 Pole and field coil stripping and cleaning
1) The pole body shall be cleaned of all paint, grime, and other contaminants using glass bead shot or
equivalent. The pole body shall be covered with plastic sheeting once cleaned to protect against
airborne contaminants while waiting for the coil assembly. Refurbish damper winding contact areas
if necessary.
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IEEE Std 1665-2009
2) The coil brazing shall be inspected and re-brazed if necessary. If new copper is required, then
specify CDA# C10200.
3) The coil assembly shall be cleaned in order to allow proper adhesion of the insulation and epoxy.
All burrs and sharp edges shall be removed.
L.2.2 Coil braces
The Contractor shall supply new insulation and lock plates.
L.3 Material requirements and workmanship
1) The supply of one set of top and bottom pole collars is required. Collar material shall be NEMA
GP01 material or equivalent.
2) The inter-turn and pole body insulation shall consist of Class 155 materials. Coil turns and
insulation shall be consolidated with Class 155 epoxy by heating and pressing at a force equivalent
to the runaway speed-related angular and radial acceleration force.
3) All necessary packing, blocking, and insulating materials required to properly re-install the field
pole assemblies shall be included in the completed assembly and shall be Class 155.
4) The unique identity of each coil-to-pole body number shall be maintained through all rebuilding
operations. Also, the longitudinal orientation of each coil relative to the pole body shall be
maintained.
5) The overall height of the field pole winding plus top and bottom collars shall be such that when the
pole assemblies are in their finished state, the pole body iron shall be proud of the collar by
0.25 mm to 0.76 mm (0.010 in to 0.030 in).
6) The field pole assemblies shall be completely assembled at the Contractor’s facility.
7) Field poles received at site shall be in the “ready to install” state.
8) New keys shall be provided for dovetail poles and lock plates if required for bolted on poles.
L.4 Testing
1) All coils shall be mounted on their respective field poles before being tested for short circuited
turns by means of an impedance test. A record of the voltage, current, watts, and power factor shall
be kept. This information shall demonstrate that all coils are free of turn-to-turn short circuits and
shall be used for future reference.
2) Mounted coils shall withstand a 5 kV dc high-potential test for one minute or a 10 times operating
voltage ac test for 1 min. The leakage current at the one minute mark shall be recorded.
3) Each coil shall be subjected to a 1 kV surge test using an RSO test set. The resulting waveform as
seen on the display on the test set shall indicate that shorted turns are not present.
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IEEE Std 1665-2009
L.5 Required information *

1) If any modifications to the coil leads are necessary in order to accommodate a new type of coil-to-
coil connector, a drawing of the proposed modification is required. This drawing shall be approved
by the Engineer before any modifications begin.
2) One copy of the test data from all tests conducted shall be shipped with the pole body assemblies.
L.6 Shipping
1) The Contractor shall be responsible for both pickup and delivery of the field pole assemblies.
2) When the pole assemblies are shipped back to the plant, the pole body assemblies shall be shipped
in a manner that will protect the pole body assemblies from physical and environmental damage.
Each pole shall be identified with a unique number that indicates its original location on the rotor
rim/spider. Pole bodies shall be shipped with a moisture absorbing medium and via a closed truck.
L.7 Warranty
All new materials and workmanship shall be guaranteed for at least one year after the generator is returned
to service.
98

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IEEE Guide for the Rewind of

Electric Machinery Committee

Approved 11 September 2009

The Institute of Electrical and Electronics Engineers, Inc.

Copyright © 2010 by the Institute of Electrical and Electronics Engineers, Inc.

Dacron® is a registered trademark of Invista, Inc.

Kingsbury, Inc.® is a registered trademark of Kingsbury Incorporated.

PDF: ISBN 978-0-7381-6064-1 STD95970

Secretary, IEEE-SA Standards Board

Laws and regulations

Updating of IEEE documents

William H. Bartley, Chair

John Amos James Grant Beant Nindra

William J. Ackerman Gary Heuston Jerry Murphy

Robert M. Grow, Chair

John Barr Alexander Gelman David J. Law

Howard L. Wolfman, TAB Representative

3. Definitions; acronyms, and abbreviations; and special terms..................................................................... 3

4. General issues, strategies, and objectives for rewinding ............................................................................ 5

5. Generator stator winding considerations .................................................................................................... 9

6. Generator rotor considerations ................................................................................................................. 14

7. Writing the technical specification ........................................................................................................... 19

Annex B (informative) Glossary of commonly used generator terms .......................................................... 30

Annex C (informative) Generator components and auxiliaries .................................................................... 39

Annex D (informative) Stator rewind information ....................................................................................... 47

Annex E (informative) Cylindrical rotor rewind information ...................................................................... 54

Annex F (informative) Salient-pole rotor rewind information ..................................................................... 62

Annex G (informative) Information typically supplied in a specification by Owner or Vendor .................. 65

Annex H (informative) Typical preparations for a rewind specification...................................................... 68

Annex I (informative) Typical stator rewind specification for turbo-generators.......................................... 72

Annex J (informative) Typical rotor rewind specification for turbo-generators........................................... 78

Annex K (informative) Typical stator rewind specification for hydrogenerator .......................................... 86

IEEE Std C37.102™, IEEE Guide for AC Generator Protection.

3. Definitions; acronyms, and abbreviations; and special terms

mil: One thousandth of an inch.

3.2 Acronyms and abbreviations

FME: foreign material exclusion

MSDS: material safety data sheets

NDE: non-destructive examination

OEM: original equipment manufacturer

OFC: oxygen-free copper

OFHC: oxygen free, high conductivity

PD: partial discharge

RF: radio frequency

RTD / TC: resistance temperature detector or a thermocouple

VPI: vacuum pressure impregnation

3.3 Special terms

4. General issues, strategies, and objectives for rewinding

4.2 Future operating modes

4.3 Reliability issues

4.4 Competitive bidding

4.5 Generator capability issues

4.5.1 Upgraded stator windings

a) Prime mover capability

4.5.2 Rotor rewinds or reinsulation upgrades

5. Generator stator winding considerations

5.2 Winding design considerations