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27 Analysisofstatorcorefaults-afreshlookattheELCIDvectordiagram Hydro2006
27 Analysisofstatorcorefaults-afreshlookattheELCIDvectordiagram Hydro2006
27 Analysisofstatorcorefaults-afreshlookattheELCIDvectordiagram Hydro2006
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Analysis of stator core faults - A fresh look at the EL CID vector diagram
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D.R. Bertenshaw
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Introduction
The stator cores of large electrical machines, such as the generators in power stations, are constructed from a
large number of thin iron laminations insulated from each other to reduce induced eddy currents and consequent
power losses in the iron. Damage to this inter-laminar insulation due to ageing effects or during normal service
can be critical, and even relatively minor defects can cause a significant increase in localised currents circulating
in the core (see fig 1). If not addressed, the resultant heating can damage the iron and winding insulation [1],
reducing machine life and even leading to catastrophic failure [2].
The Chattock magnetic potentiometer [7] consists of a Fig 2 Chattock potentiometer positioned across a
flexible, uniform, air-cored coil whose ac output is fault
proportional to the line integral of the ac magnetic field
along its length, and thus measures the local magnetomotive force (m.m.f) as a magnetic potential difference
(m.p.d.) between its two ends. It is placed across the core teeth, straddling a slot as in fig. 2, and scanned along
the slots with the results recorded.
In the EL CID test the Chattock sensor detects the vector sum of all the electromagnetic effects occurring within
the underlying core. The signal is resolved into components in phase (PHASE) and in quadrature (QUAD) with
the excitation current by a phase sensitive detector. Since the voltage induced in any fault is in proportion to the
rate-of-change of flux, the fault current can be detected as being in quadrature to the flux. Thus the resistive (heat
producing) element of the fault current component of the Chattock signal is indicated by the QUAD m.p.d.
There has been considerable new work completed in the last few years relating to the theoretical principles of EL
CID and its modelling [9], causing a review of the standard vector diagram. This has resulted in the conclusion
that this is simplistic and potentially misleading, since it fails to predict all the observed fault signals. In addition
there has been little consideration of the effect of core loss. Ridley [5] provided a more rigorous analysis based
on transformer theory, but still does not predict all results. The observed basic fault signals are that, for a fault
within the span of the Chattock, a core fault shows as a negative QUAD signal for a positive PHASE signal (and
vice-versa). In addition for an increasing QUAD fault signal, the PHASE signal increases in absolute amplitude
as well (regardless of polarity).
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When the Chattock spans a short section of core surface, its signal is the line integral of the ac magnetic field
along its length. Since the majority of the fault m.m.f. occurs in the air, this will be the sum of the fault m.m.f.
and the section proportions of the fault and excitation flux m.m.f.s. Thus the total closed path m.p.d. the
Chattock detects within its span, when set at an angle a (radians), is:
Excitation m.p.d. = - E.a/2π (note the Chattock polarity is opposite to the field)
Fault m.p.d. = F.(1-a/2π) (fault current and the proportion of the core fault flux m.m.f.)
Thus total m.p.d = F.(1-a/2π) - E.a/2π
Since a<<2π for single slot Chattock spans, total m.p.d ≈ F - E.a/2π
This proves that locally the Chattock essentially detects all the fault current m.m.f. and the inverse of the
circumferential proportion of the excitation current m.m.f. (This should not be taken to assume that the Fault
current is induced to flow in any particular direction or phase, only the magnitude and polarity of detection).
EL CID is calibrated and Phase Reset before use by calibrating the Chattock in a standardised field of 1A-t, with
the field current also providing the Reference signal via the above Rogowski coil. This process rotates the
analysis phase reference (also nulling any phase errors) to record a positive PHASE value and exactly zero
QUAD value. For this study the measured Chattock Signal is resolved by the degree it leads/lags a Reference
derived from the excitation current, as is the normal practice in use.
For a fault-free homogenous core, the excitation m.m.f. induced by the excitation current does not vary
significantly in phase angle between the excitation winding and the core surface, thus the excitation signal
detected by the Chattock on the core surface is the same phase as the excitation current itself. It is not affected by
any leakage flux from the core since normally there is none. This is due to the fact that in a homogeneous core
with central excitation, the excitation m.m.f. is uniform around the core and only circumferential (as shown in
fig. 3), thus there is no m.m.f. up or down the teeth to cause flux leakage.
The Chattock detects the m.p.d. at the core surface that is driving the flux around inside the core and supporting
the losses in the core, not the flux in the core which may be lagging the excitation by 10-25 degrees due to core
loss (described later). In fact EL CID cannot normally detect this flux. It is for this reason that there is normally
very little change between completing Chattock calibration in the Calibration unit and any final Phase Reset
done on the surface of the core.
+P, -Q -P, -Q
If the Signal phase angle leads the Reference, the QUAD value
reads positive, thus QUAD is resolved conventionally. This
gives the quadrant diagram of EL CID polarity indications for
Fig. 5 EL CID phase resolution
PHASE (P) and QUAD (Q) readings in fig. 5.
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6. The Impact of Core Loss on EL CID Detection
In a core under test, the flux significantly lags the
excitation m.m.f. due to hysteresis and eddy current 30
losses in the core, dependant on the type, age and grade
of the iron and also the excitation level. As an example, 25
The earlier observation that EL CID cannot detect the Fig. 6 Flux lag wrt excitation for M270-50A steel
actual core flux has an exception with split cores in
hydro-generators. As shown in section 11, the m.m.f. across a split is dominated by the impedance of the loss-
less air gap, and the phase angle of the m.m.f. across the split slot will closely approach that of the flux. Since
Digital EL CID records the phase reset angle reference for each slot as well as the detailed PHASE and QUAD
values, it is possible to use the EL CID results to determine the approximate angle of the flux from the difference
in the fault-free readings between the main core (readings = excitation m.m.f. ) and the splits (readings ≈ core
flux). From a short survey of 6 split-core, hydro-generator EL CID results, values ranged from 8 to 28 , with
most in the 15-20 region.
From these a combined vector diagram can be drawn showing the addition of the Excitation m.m.f. and the
Induced fault m.m.f, resulting in a combined Chattock signal in fig 7a. The polarity and direction of the resolved
EL CID signals is shown in fig 7b. From this it can be seen that the PHASE signal mostly consists of the
Excitation current, and the QUAD signal is solely proportional to the induced Fault current.
Phase rotation
Resolved PHASE Excitation Current Excitation Current
signal at Chattock and Reference
Core loss
Induced Fault Current
Excitation Flux Ф
Resolved QUAD
signal QUAD +ve
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This allows the observed phenomena to be fully explained. For a positive PHASE signal, the QUAD signal is
negative for a fault within the Chattock span. In addition, the presence of a modest fault (small inductive
element) causes a small increase in the PHASE signal, which increases substantially as the fault becomes more
severe due to inductive lag causing the induced fault current to become more in phase with the PHASE axis.
As variations and extra contributions are considered on the above diagram, it becomes more convenient if the
signals that are usually summed vectorially into a combined Chattock signal are instead drawn separately. Since
the EL CID system displays the resolved PHASE and QUAD values, not the combined vector, this allows an
easier understanding of the contribution to PHASE & QUAD values of each signal, especially since some may
be inverted depending on test configuration. The resultant component vector diagram is drawn in fig. 8.
Phase rotation
Excitation Current Excitation Current
at Chattock and Reference
PHASE
signal Core loss
Excitation Flux Ф
Induced Fault Current QUAD QUAD +ve
signal
In turbo-generators circulating currents are usually caused by off-centre excitation, which “over-excites” the
nearer region of core and induces circulating currents in windings in parallel. With normal central excitation the
m.m.f. is solely circumferential and with no radial m.m.f. there will be no flux flowing up/down any teeth. In this
case the excitation flux will induce balanced voltages of the same polarity on all conductors, so no net voltage
will appear on any winding.
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The impact on the vector diagram is dependant on whether the Chattock is spanning a slot that contains a
circulating current flowing in the same direction as that induced, or the opposite direction in a return slot. For
study it is assumed in the same direction. The induced voltage in the winding will be 90° lagging the excitation
current (local induction flux), and the resultant circulating current will lag the induced voltage by >80°.
The resultant full vector diagram is drawn in fig. 10, adding in the circulating current vectors. (The induced fault
current in phase with the voltage is deleted for clarity). From this it can be seen that the impact on the QUAD
readings will normally be small by comparison with the PHASE readings, with a small negative increase in
QUAD for substantial positive increase in PHASE (both inverted for currents flowing in reverse slots).
PHASE +ve
However in larger hydro-generators, the presence of splits in the core causes the core magnetic circuit to have a
major discontinuity at these points. Cores may have two, three or more splits depending on size, with each split
central in a slot back or less commonly in a tooth centre, and circulating current is readily induced in generator
windings by these core splits. A common arrangement is shown for investigation in fig. 12 with the windings in
a slot at or near a core split. When the excitation winding is not in close proximity, the flux that induces
imbalanced voltages in the hydro-generator windings is the leakage flux around the split as the flux across it.
Since the core flux must cross the split, and the split is air and has no loss, the resultant m.p.d. and leakage flux
across the split is in phase with the core flux. The leakage flux linking the winding is normally a few % of the
core flux. If the split is in the tooth, then the split will still cause leakage flux induction of the two adjacent
windings, though to a lesser extent. (Again the situation is more complex in practice as split flux leakage will
also affect other windings in nearby slots to some extent).
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In this case the winding net induced voltage will be
in opposite phase to that normally induced by the Generator winding Local induction (leakage) flux
excitation flux, since the leaking local induction
flux is flowing in the opposite direction around the
winding to the main core flux. The resultant normal
vector diagram is drawn in fig. 13, adding in the
circulating current vectors for a winding with the Excitation flux Ф
current flowing in the induced direction. It must be
stressed that this diagram is for slots sufficiently
distant from the split to not be directly affected by
the leakage flux, but which happen to include a Core split
generator winding that is carrying circulating
current in the same direction as that induced in the Fig. 12 Hydro-generator circulating current induction
winding at the split. The situation at the split is
discussed later.
From this it can be seen that the impact on the QUAD readings will again still be small, though potentially
greater than with turbo-generators. In this case it is possible, with a low resistance winding, for the circulating
current to induce a negative increase in QUAD signal for a negative increase in PHASE signal (again inverted
for currents flowing in reverse slots).
Induced Winding
Voltage
Excitation Flux Ф
PHASE +ve
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To illustrate the relative magnitudes of these m.m.f.s, for an example in a core of 100mm slot pitch with a
0.5mm wide split and an iron relative permeability of 2000, the core split (air-gap) reluctance is 10x the non-split
iron. This will mean that a core loss m.m.f/flux lag of typically 20° will reduce to around 2° at the split.
The resultant component vector diagram is drawn in fig. 15. In order to demonstrate the relative magnitude of
the Split m.p.d., the Excitation current m.m.f. has been scaled down.
In this it can be seen that the effect of the large split m.m.f. is to generate a very large PHASE signal, and to
impose a substantial positive QUAD signal on top of any negative fault QUAD signals, both consistent with
practice. In addition, the amplitude of the imposed QUAD signal from the split will vary in direct proportion to
the size of the split. This will make analysis of any fault signal difficult, as splits are rarely uniform.
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12. Vector Diagram for Phase Reset at Split
Due to the disturbance of the QUAD signal at splits, it has long been advised that users should perform a Phase
Reset with the Chattock placed across the split. This sets the Reference signal direction such that the effect of
split m.m.f. is minimised. When this is done in fig. 16, the Reference direction is rotated to make the combined
effect of the excitation and split m.m.fs on QUAD = zero. Thus the effective Phase Reference is the net vector of
Excitation current m.m.f. + Split m.m.f, and the Excitation Flux is now almost on the Reference axis.
Excitation Current
Phase rotation
PHASE +ve
This shows that the effect of variations in the split geometry affecting the QUAD signal are now much reduced.
Ideally the reference direction would be the Excitation flux itself, however this is not directly accessible to EL
CID other than by a flux search coil as Reference input.
13. Vector Diagram with Phase Reset at Split and Circulating Current in the Winding
Since the Induced Winding Voltage is orthogonal to the Flux it is nearly on the QUAD axis, thus the induced
current in the inductive winding shown in fig 17 will be almost on the PHASE axis. Depending on exact winding
impedances (resistive/reactive), there may be a small residual addition or subtraction to the detected QUAD
signal, but the effect on QUAD of circulating winding currents at the split, induced by the split, are usually
small.
Induced Winding
Voltage
Excitation Current
Phase rotation
Split m.m.f. at
Chattock Induced Winding Current
Fig. 17 Phase Reset split core vector diagram with circulating current
-9-
14. Influence of Core Splits on Overall Excitation
The presence of core splits in hydro-generators will have an effect on the overall excitation. In an example of a
10m diameter generator (~30m active core circumference) with 2 core splits of 0.5mm gap and relative
permeability of 2000, the total impedance of the splits is equal to about another 2m of core iron. For the total
magnetic circuit of 2 air-gap splits and 2 iron sections, with core loss lag assumed at ~20°, the total m.m.f.
required to drive the test flux is shown in fig. 18.
Since the only source of m.m.f. in the system is the excitation current, this shows that the excitation current will
have slightly less lead on the core flux than the m.m.f. across the core sections, and the total current drawn will
moderately increase over a non-split identical core. In this case there will also be a small difference (~1-2°)
between a Calibration Phase Reset and a Phase Reset on the non-split core region.
Excitation flux Ф
15. Conclusions
This work completes a more rigorous study of the electromagnetic detection processes at work in the EL CID
test. The importance of (natural) core loss is shown in the analysis and how this affects the resolution of the fault
currents. The different methods whereby circulating currents can be induced and their effect on test results is
described. The fact that EL CID does not directly detect the excitation or fault flux but only the magnetic
potentials caused is demonstrated, and the impact on the test results shown. In the particular case of large split-
core hydraulic generators the impact of the split on the test results and any circulating currents is analysed, and
demonstrates how the recommended test techniques can greatly ameliorate the interfering effect of the large
m.m.f. at a split.
References
1. Taillon, J, “Experience with EL CID Test Values above the Acceptable Threshold”, EPRI – International Workshop on
Maintaining Integrity of Generator Cores, USA, November 2001.
2. Murray S. J. et al, “Modelling Fault Propagation in an Electric Generator Stator Core”, EPRI Generator Workshop,
Albuquerque, USA, July 2003.
3. UK Patent 2044936, “Method of and apparatus for testing laminated magnetic cores”, 1979.
4. Technical Brochure 257, “EL CID (Electromagnetic - Core Imperfection Detector) Testing of Large Steam-Turbine
Driven Generators”, CIGRE, Paris, 2004.
5. Ridley, G.K., “EL CID – Application and Analysis”, 2nd edition. Book published by ADWEL International Ltd, 2004,
ISBN 0-9539465-0-9.
6. Sutton, J., “Theory of Electromagnetic Testing of Laminated Stator Cores”, IEE Insight Vol. 36 No.4, April 1994.
7. Chattock, A.P., “On a Magnetic Potentiometer”, Phil. Mag. Vol. 24, No. 146, July 1887.
8. Bertenshaw, D. and Sutton, J., “Application of the EL CID Test with Circulating Currents in Stator Windings”,
Proceedings, Inductica, Berlin, 2004.
9. Bertenshaw D, Chan T, Smith S, Ho C, “Computational modelling of stator core faults in large hydro-generators and
turbo-generators”, Hydro 2004, Portugal
The Author
David Bertenshaw, Director of Product Development and UK Operations, ADWEL International Ltd.
David Bertenshaw holds a B.Sc. (Eng) degree in electrical engineering from Imperial College, London, is a FIEE and a
Chartered Eur. Ing. He has spent many years in the development of electrical and electronic lighting, control and
communications systems as an R&D Director, managing teams in the UK, USA and Italy. He joined ADWEL International
in 1998 to direct the European commercial operations and engineering of ADWEL’s stator core test systems. He has authored
20 conference papers and is inventor on 6 international patents.
Contact: Tel: +44 1923 254433, Fax: +44 1923 218278, Email: dbertenshaw@adwel.co.uk
Acknowledgements
The author gratefully acknowledges the support and valuable comments given by Derek Paley, John Sutton and especially
Kenneth Ridley.
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