IDENTIFICATION OF VIBRATION SPARKING WITH EMI DIAGNOSTICS

James E. Timperley Doble Engineering

ABSTRACT
This paper discusses the detection and identification of vibration sparking or the spark erosion of generator stator bars. A theory for the unique EMI pattern developed is discussed. Validation of stator repairs is also provided.

Typical Vibration Sparking Deterioration of a Stator Bar FIGURE 1

INTRODUCTION
A few designs of modern generators have suffered stator failures within the first years of service due to a condition called vibration sparking. The reason behind this rare failure mode, sometimes referred to as spark erosion, is the subject of some debate but in general it is felt the conductivity of the stator bar slot coating is too high. This carbon based coating is applied to prevent high voltage partial discharges in the slots. If the coating is too conductive circulating currents through the core laminations may develop. At the bore of a large generator, several hundred volts can be induced axially from one end of the stator core to the other. Circulating currents from this voltage are prevented in the core by insulation on each of the hundreds of steel core laminations. These laminations are however electrically connected to each other and the frame at the back of the core. If a stator bar surface is too conductive, a loop is formed with the core frame and high circulating currents can result. This current is only limited by the resistance of the stator bar coating. Electromagnetic Interference (EMI) Diagnostics has been developed as a system wide surveillance technique that can detect and identify electrical defects in motors, generators, isolated phase bus, transformers or associated electrical systems. EMI is a frequency domain technique that scans a wide frequency range for meaningful information. Partial discharge analysis (PDA) is a time domain technique that only looks at selected parts of the spectrum. The purpose of this paper is to identify the EMI signature for the vibration sparking failure mode. Four generators with different stages of deterioration were tested and the results are presented in this report. EMI Basics EMI is generated by energy conversion from the power frequency to radio frequencies at the site of a defect. This activity can originate from a high voltage low current discharge (partial discharge) inside or on the surface of insulation. Another EMI source is from a low voltage high current arc such as with broken conductors, loose connections or shaft currents through a wiped bearing. This ability to detect arcing defects in conductors is a major advantage of the EMI technique over partial discharge analysis where only the insulation is monitored. There are many mechanical sources of arcing, and vibration sparking can be added to the list. The Tests Three of the four generators tested had been rewound. The fourth stator rewind was the last one scheduled before a failure developed. One of the stators had received additional repairs after the stator rewind and two machines had not. These four air cooled generators are rated 226 MVA, 18 kV, 3600 r/min. The generator load during data collection varied from 145 to 160 MVA depending on the machine. Operation varies with the time of year but these machines usually run 24/7.

EMI Signature of Unit 1 FIGURE 2

The EMI signature for Unit 1 in Figure 2 is typical of what would be expected for a generator in good condition. This generator stator had been replaced about six months before this data was collected. Exciter diode noise dominates the lower frequencies. Local radio transmitters, power line carriers (PLC), and AM and FM stations all have amplitudes higher than the generator related activity. Minor generator related PD was noted. There is some PD activity on the 345 kV transmission line that can be detected above 10 MHz.

EMI Signature of Unit 2 FIGURE 3 Unit 2 has the original stator winding and was scheduled for rewinding. Spark erosion of the stator bars was advanced. High random noise patterns were noted across the spectrum. No typical PD activity was noted. Radio stations were at very high amplitudes.

EMI Signature of Unit 3 FIGURE 4

This stator has been rewound and operated about a year when this data was collected. Local radio stations were measured with high amplitudes. Stator related random noise was detected at several frequencies. The 345 kV transmission line PD activity was detected above 10 MHz.

EMI Signature of Unit 4 FIGURE 5

This stator had been rewound and operated several years when this data was collected. Additional enhancements have been made to the rewound stator. Side ripple springs were installed about a year before this data was collected. Stator related EMI was at very low levels. This validates that the additional stator repairs were successful in reducing the spark erosion activity.

EMI Signature Comparison FIGURE 6

There are major differences in the low frequency part of the spectrum, and again around 2-4 MHz, then also around 30 MHz. Due to the location near a major city the local radio transmitters have very high amplitudes.

Unit 2 & Unit 4 EMI Signature Comparison FIGURE 7

Unit 2 had the highest EMI levels and Unit 4 had the lowest. No significant stator related PD activity was noted with Unit 4. Unit 2 had a pattern of random noise and low level arcing across the spectrum. Random noise is usually associated with the accumulation of conductive contamination on a stator winding. It is unusual for random noise to be at these frequencies and at this high a level.

Unit 4 EMI pattern @ 56 kHz FIGURE 8

The exciter pattern for Unit 4 is as expected. When exciter diodes stop conducting transients are produced and can be measured by their EMI pattern. There are no problems with this exciter, no loose connections, no open circuits or weak diodes are present.

Unit 2 EMI pattern @ 56 kHz FIGURE 9

The pattern at 56 kHz should be dominated by exciter diode transients but these are almost completely hidden by the high level random noise. Several hundred generators have been tested and none have had this pattern of extreme random noise at the low frequencies.

Unit 2 EMI Pattern @ 6.7 MHz FIGURE 10

The EMI pattern noted at 6.7 MHz is typical for this part of the EMI signature for Unit 2. There are no partial discharge spikes present. The random noise is mixed with low level arcing. There appears to be little synchronization with the power frequency. This pattern made a sizzling sound. It appears that a combination of low level arcing and random noise are the EMI patterns generated by vibration sparking or spark erosion.

Random Noise Sources Every electrical conductor produces an irregularly varying voltage across its terminals as a result of the random motion of the free electrons in the conductor caused by thermal action. This is often called Johnson-Nyquist noise and is continuous across the radio frequency spectrum with uniform amplitude. This voltage is however usually very small. Thermal agitation noise does not depend on applied voltage or current flow through the conductor. The voltages are small and EMI is not developed in most cases. Noise voltage also arises from the small random variations in current flow through a conductor. The amplitude of this random noise is proportional to the temperature, resistance and applied voltage. It also depends on the conductor material. In the electronics industry it is well known that resistors composed of carbon granules generate high levels of electric noise when current flows through them. This noise voltage results from fluctuations in contact resistances between adjacent particulate carbon granules, a consequence of the heterogeneous structure. The noise voltage generated is due to that variation and is proportional to the amount of current flowing. Even small vibrations of a stator bar and the conductive carbon layer with respect to the grounded core would generate noise. This property was used for the first telephone microphones where sound vibrations changed the contact resistance between carbon granules and produced current flow related to sound vibrations. Random noise is one of the EMI patterns documented along with gap discharges, corona and arcing. In the past this pattern has been associated with the accumulation of conductive contamination such as coal dust on a stator
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winding. Typically the EMI signature is a peak of random noise developing around 1 MHz. This peak increases as the deterioration increases. This has been a useful characteristic to rank 4 kV motors in need of cleaning. Slot Coating Deterioration Vibration sparking or spark erosion of the conductive layer on a stator bar is different from the typical partial discharge erosion. Figure 11 shows the typical deterioration that develops. Bars at any location in the winding, both line and neutral, have developed the same distinctive pock marked pattern. Deterioration starts where the bar is in contact with the core teeth and is less at the air vents. These pits are very similar to what develops on Babbitt bearings resulting from shaft currents.

Slot Coating Deterioration Resulting from Vibration Sparking FIGURE 11

There is little bleaching of the materials in the sample in Figure 11, this would indicate the sample is not a high voltage bar. Burning of the carbon coating and resin as well as melting of the glass tapes indicate very high temperatures were developed. This also implies very high currents are also present. With this generator design there is around 800 volts axially from one end of the core to the other. The conductive slot coating shorts out this voltage and current flows along the bar surface. Arcing type activity is the result of the bar conductive coating making and breaking contact with the core. Sparking activity is greatest during the peaks of vibration. Random noise results from current flow through this long carbon resistor. If a high voltage bar is involved then conventional PD develops as the slot coating is removed. If a low voltage bar is involved there is no PD and no ozone bleaching develops.

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Partial Discharge Deterioration of a Stator Bar FIGURE 12

Classic bleaching of the conductive coating is present when PD is the only deterioration mechanism. There was no bar vibration with this generator and there are no core lamination imprints on the side of the bar. The glass cloth backing for the carbon based conductive coating is bleached white from the PD generated ozone. There is no melting of the glass and no burning of the carbon or resin.

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Side-Packing Deterioration from Spark Erosion Looks Like Burning FIGURE 13

Side-Packing Deterioration from PD is Totally Different. FIGURE 14

As with stator bar deterioration there are marked differences in the deterioration of the conductive side packing used to hold stator bars tight in the slots. Flat side packing, not side ripple springs are shown in the two examples above. Spark erosion deterioration often burns the conductive packing resin and carbon filler. PD will only destroy the carbon filler and resin binder, leaving the clean bright glass cloth.

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CONCLUSION
EMI Diagnostics is able to detect and classify the deterioration from vibration sparking or spark erosion of stator bars. This type of deterioration is unique and a unique signature is developed. Trending of the EMI signature and patterns can provide information on deterioration rates. The verification of stator repairs can also be determined by a second diagnostic test. Spark erosion will be added to the numerous other generator system defects and types of deterioration can be detected and identified.

BIOGRAPHY
James E. Timperley (BSEE, 1968 Oklahoma State University) began working in the utility industry with American Electric Power. He was involved with station engineering the R&D laboratory and rotating machinery. He retired from AEP after 38 years of service and joined Doble Engineering in 2007. Jim has published over 70 technical papers on operating, maintaining, testing, advanced insulation materials and repairing rotating electrical machinery. Other activities include maintaining high current isolated phase bus, equipment root cause failure analysis, and the development and application of EMI Diagnostics. Mr. Timperley is an IEEE Fellow and was presented the 2006 Dakin Award by the IEEE Dielectric & Insulation Society for the development of EMI Diagnostics. He is currently active in several standards groups and is a registered professional engineer in the state of Ohio.

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