GE Energy

Partial Discharge Analysis Sensor Installation Instructions

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be desired or
should particular problems arise which are not covered sufficiently for the purchasers purposes the matter should be
referred to the GE Company y

g
GENERAL ELECTRIC COMPANY
Schenectady, NY
GE Power Generation
DT- 2N VENDOR SUPPLIED DRAWING
GE NOT TO REVISE. GE REV. LEVEL IS AS SHOWN ON THIS APPLIQUE.
THIS DOCUMENT IS FILED UNDER THE GE DRAWING NUMBER.
THIS DOCUMENT SHALL BE REVISED IN ITS ENTIRETY. ALL SHEETS OF THIS
DOCUMENT ARE THE SAME REVISION LEVEL AS INDICATED IN THIS VENDOR
FIRST MADE FOR: SH 1
GE SIGNATURES DATE GE DRAWING NUMBER REV.

CHECKED: A. Krass 18DEC08

385A3330 C
ISSUED: A. Krass

1
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

Table of Contents

I. GENERAL DESRIPTION 3
A. BACKGROUND 3
B. EQUIPMENT OVERVIEW 4
C. PDA SENOR SPECIFICATION AND PARTS LIST 6

II. INSTALLATION 10
A. UNPACKING AND INSPECTION 10
B. SENSOR LOCATION AND MOUNTING 11
C. CO-AXIAL CABLE CONNECTIONS 16
D. GROUND CONNECTIONS 16
E. TERMINAL BOX CONNECTIONS 17
III. MAINTENANCE 19
IV. MARKING 20
APPENDIX A INSTALLATION DRAWINGS 21

For support of all aspects of the Partial Discharge Analysis system, including, but not
limited to, technical specification, performance, maintenance, installation, modification, or
field support, please contact GE Inspection & Life Extension Services through your local
GE service representative. All change activity including Design Change Initiative (DCI)
authoring, disposition of Service Notices (S/N), Quality Control Reports (QCR), Supplier
Deviation Requests (SDR) or Power Answer Center (PAC) inquiries or bill of material
maintenance is the responsibility of GE Inspection & Life Extension Services (I&LES).

2 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

I. GENERAL DESCRIPTION

A. Background
Partial discharge analysis is an effective tool to monitor generator insulation health and
track the long-term degradation process. Although the measurement and analysis of
partial discharges is not new technology, the recent development of a phase-resolved
analysis and the use of three (3) capacitive couplers has resulted in the ability to provide
a more comprehensive picture of machine condition.
The generator stator winding insulation system is designed to operate with partial
discharge, and the gradual degradation of insulation, referred to as aging, is a normal
process throughout the service life of the insulation system. Partial discharges are high
frequency, low voltage pulses that may be initiated by a variety of equipment operating
conditions.
Used in conjunction with the other recommended electrical tests, partial discharge
analysis can provide a comprehensive description of the generator condition and help in
pre-planning of generator maintenance.

Some of the conditions that can develop, which might result in increased partial discharge
activity are:

Aging of stator bar insulating materials resulting in voids in the insulation.

Stator bar vibration and / or abrasion.
Damage to the end winding voltage suppressor (grading)
system. End winding contamination and corona.
Connection ring vibration.
Broken conductors.
Collector brush sparking.

Some of the benefits of PDA are:

Non-invasive.
May be performed on or off-line.
Indicates condition of generator insulation system.
Identifies detrimental trends.
Compares identical units, aids outage planning.
Augments conventional test & inspection methods
Provides for condition-based maintenance.

This document summarizes PDA sensor equipment and installation guidelines.

Information on separately available PDA monitoring equipment is not included. This
information is available in other GE documentation.

3 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

B. Equipment Overview

GE currently offers PD sensors in two ratings a 20 kV AC/6 sensor and a 27 kV

AC/10sensor. The high voltage end of the sensor is connected to the line leads of the
generator for either sensor rating (See Figures 1 - 2).

PDA equipment consists of three sensors (couplers) that are installed in the generator
terminal enclosure or the iso-phase bus duct.

The 20 kV AC/6 sensor (See Figure 3) is rated for application on generators with terminal
voltage rating as high as 20 kV AC; this sensor has a 125 kV BIL rating. The 27 kV
AC/10sensor (See Figure 4) is rated for application on generators with terminal voltage
rating as high as 27 kV AC; this sensor has a 165 kV BIL rating.

NOTE
Installation in round Iso-phase bus duct requires base plates that
are curved to the arc of the specific duct; these plates are special
ordered and do not ship as part of the standard PDA kit.

Bushing

Figure 1. Conceptual Diagram of PDA Sensor

Each sensor is comprised of two capacitors encased in an epoxy molded bushing, and a
high frequency current transformer (HFCT) as shown in Figure 1. The sensors are
grounded and, during test, the HFCT is connected to a data interface/acquisition unit,
which provides monitoring of the insulation PD activity.

4 of 21
DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

5 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions
C. PDA Sensor Specifications and Parts List

The PDA sensor has been designed for collecting partial discharge signatures from high
voltage rotating machinery. The sensor construction allows for easy installation near the
machine terminals, improving signal strength and signal to noise ratio. The sensor is
designed according to ANSI 29.7-1983, section 5.2, and to GE Canada Insulation
Systems reports 90RH01 recommendations regarding corrosion, track-resistance,
flashover, thermal-ratings, etc. The sensor meets all material specifications of the IEEE
STD C37.20.2-1993, section 5.2.6.2, which is valid for assemblies rated 8.25kV and
higher. It has been tested to ANSI D2303-90 under Condition A.

Figure 3. Uninstalled PDA Sensor (20 kV AC/6).

Physical Dimensions: 6 x 5 x 5
Capacitance 900 pF
AC Rating: 20 kV AC
Corona-free up to: 24 kV AC
Hipot Rating: 24 kV AC
3E+1 kV DC for 1 minute (E=20KV)
BIL (lightning strike) Rating: 125 kV
Thermal Rating: 1 C 105 C
Signal Source: HFCT, Max output 110.0 m volts
Frequency Range: 40 kHz 150 MHz
Mounting location: Requirements:
(Recommended distances Electrical clearances per Table 3.
or Recommendations:
cable lengths; shorter is All sensors within 12 from generator phase bushing
preferable) connections.
Each sensor within 4 along phase lead from other
Operation: Continuous availability of on-line PD measurements
Total Weight: 5.2 pounds
Certifications:

CE x II 3 G, EEx nA IIC105C

Table 1. 20 kV AC/6 PDA Sensor Specifications

6 of 21
DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

Figure 4. Uninstalled PDA Sensor (27 kV AC/10)

Physical Dimensions: 10.5 x 5 x 5

Capacitance 900 pF
AC Rating: 27 kV AC
Corona-free up to: 35 kV AC
Hipot Rating: 40 kV AC
3E+1 kV DC for 1 minute (E=27KV)
BIL (lightning strike) 165 kV
Rating:
Thermal Rating: 1 C 105 C
Signal Source: HFCT, Max output 110. 0 m volts
Frequency Range: 40 kHz 150 MHz
Mounting location: Requirements:
(Recommended distances Electrical clearances per Table 3.
or cable lengths; shorter is Recommendations:
preferable) All sensors within 12 from generator phase bushing connections.
Each sensor within 4 along phase lead from other sensors.
Cable length between sensors and terminal box < 20.

Operation: Continuous availability of on-line PD measurements

Total Weight: 8.2 pounds
Certifications CE x II 3 G, EEx nA IIC105C

Table 2. 27KV AC/10 PDA Sensor Specifications

7 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

Terminal Box

Figure 5. PDA Kit #357A2528P0003 (20 kV AC / 6) Parts

Model # PDA 100A

Part # DWG # Quantity Item Description

1 194D8491P1 3 PDA Sensor

2 194D8491 P2 3 PDA Sensor Base Plate
3 194D8491P3 3 Connection Box (4.75 x 4.75 x 3.25) Connection Box
(4.75 x 4.75 x 3.25) w/ Gasketed cover plate for
Connection Box
4 194D8491P4 6 Lock Plates
5 194D8491P5 12 3/8-16X1 Hex Head Bolts
6 194D8491P6 3 Strain Relief for Connection Box
7 194D8491P7 12 Crimp Terminals for RG-58U Cable
RG-58A/U Cable (High Temperature) (3 X 20 ft w/ connector on one end)
8 194D8491P8 60 ft.
9 194D8491P9(not shown) 3 1 ft. AWG#14 Braided Wire Leads & high voltage connection hardware
10 194D8491 P 10 (not 6 #10 Terminal for Braided Wire Leads
11 194D8491 P 11(not 0 Curved PDA Sensor Base Plates (Special Order)
12 194D8491 P 12 (not 2 Heat Shrink for lugged end
13 194D8491 P 13 (not 2 Heat Shrink for lugged end
14 194D8491 P14 (not 0 Heat Shrink for High Voltage wire connections in forced air cooled
Shown) connection areas.
** 194D8493P1 1 NEMA 4x BNC Terminal see Drawing 240C2224

Table 3. PDA Kit #357A2528P0003 (20 kV AC / 6) Parts List

8 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

NEMA Terminal Box

Figure 6. PDA Kit #357A2528P0001 (27 kV AC/10) Parts

Model # PDA 100B

Part # DWG # Quantity Item Description

1 194D8492P1 3 PDA Sensor
2 194D8492P2 3 PDA Sensor Base Plate
3 194D8492P3 3 Connection Box (4.75 x 4.75 x 3.25) Connection Box
(4.75 x 4.75 x 3.25) with gasketed cover plate for
connection box
4 194D8492P4 6 Lock Plates
5 194D8492P5 12 3/8-16X1 Hex Head Bolts
6 194D8492P6 3 Strain Relief for Connection Box
7 194D8492P7 12 Crimp Terminals for RG-58U Cable

8 194D8492P8 60 ft. RG-58A/U Cable (High Temperature) (3 X 20 ft w/ connector

one end)

9 194D8492P9(not shown) 3 1 ft. AWG#14 Braided Wire Leads & high voltage connection
hardware
10 194D8492P10 (not shown) 6 #10 Terminal for Braided Wire Leads
11 194D8492P 11(not shown) 0 Curved PDA Sensor Base Plates (Special Order)
12 194D8492P12 (not shown) 2 Heat Shrink for lugged end
13 194D8492P13 (not shown) 2 Heat Shrink for lugged end
14 194D8492P14 (not shown) 0 Heat Shrink for High Voltage wire connections in forced air-cooled
connection areas.
** 194D8493P2 1 NEMA 4x BNC Terminal see Drawing 240C2224

Table 3. PDA Kit #357A2528P0001 (27 kV AC / 10) Parts List

9 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

II. INSTALLATION

A. UNPACKING AND INSPECTION

1. Inspect the equipment for shipping damage as it is unpacked. Check closely for
broken parts (e.g. chipped or cracked sheds on the PD couplers), disconnected
wires, etc.

2. If the PDA equipment is damaged in any way, notify carrier immediately. For
assistance of any kind, contact your GE service representative.

3. Handle the PDA sensors with extreme care -- particularly on horizontal mount
installations. If any surface cracking is noted the sensor should not be placed into
service.

4. Verify the supplied couplers are appropriately rated for the generator line voltage.

Figure 7. 20 kV AC/ 6 or 27 kV AC/ 10 PDA Sensor Mounted in Iso -phase Bus Duct
(GE drawing 194D8491 or 194D8492). For round bus ducts use two rounded base
plates, one on inside, one on outside of duct (see drawing 132E4225). Explosive
Atmosphere Seal: For operation in an explosive atmosphere seal the sensor bulkhead
feed-through.

10 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

B. SENSOR LOCATION AND MOUNTING

To optimize performance, the PDA sensors must be connected to the generator phase
connections as close to the generator output bushings as is physically and safely possible.
The distance between generator output bushings and PDA sensor mounting location
should never exceed 12 feet. If the sensors must be mounted at different distances from
the generator output bushings, they should be mounted within 4 ft. of each other along the
bus path. It is also recommended that the PDA sensors be mounted in a location that is
physically accessible so that the sensors can be disconnected from the high voltage bus
bar if the generator is to be Hipot tested above the PDA sensor ratings. Sensor Hipot limits
are listed in the PDA Sensor Specification section of this document.

WARNING

LOCK AND TAG OUT THE HIGH VOLTAGE BUS PRIOR

TO PERFORMING WORK ON THE PD SENSORS. THE
BUS MUST BE GROUNDED WHILE WORK IS BEING
PERFORMED.

CAUTION

Disconnect PD sensors from the high voltage bus prior to

performing hipot testing on the bus. Failure to disconnect
may damage the sensors if bus hipot values exceed the
sensor rating.

NOTE

Installation details will vary with site-specific requirements;

however, the following general installation guidelines
represent the recommended approach for installation on
typical generating units.

11 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

1. Determine if there is sufficient clearance in the generator terminal box enclosure or the
iso-phase bus duct to mount the sensors (See Figures 3 , 4, 7 and GE PDA Equipment
Installation Drawings 132E4225). If there is not sufficient space in the terminal box
enclosure to mount the sensors, the sensors must be installed in the iso-phase bus
duct. In this case, due to typical bus duct space limitations, it may be necessary to
modify the bus duct housing to provide space to mount the sensor (See Figure 8). The
top hat modification is only needed if the distance between the bus and enclosure
does not allow coupler installation.

Make sure that the area directly outside of the enclosure will allow for clearance of the
conduit box, and that it is accessible for connecting the coupler lead wire to the
connection box terminal block.

Figure 8. Example Bus Duct Modification

CAUTION

PDA sensor electrical clearances must meet the

minimum requirements as listed in table 5.

12 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

MACHINE CLEARANCE TO CLEARANCE CLEARANCE

TERMINAL GROUND COMPONENT BETWEEN
VOLTAGE (MINIMUM) SAME PHASE PHASES
INCHES (MINIMUM) (MINIMUM)
INCHES INCHES
12-15 KV 6.00 5.50 6.00
15-18 KV 7.00 5.50 7.00
18-21 KV 7.75 5.50 7.75
21-24 KV 8.50 5.50 8.5
24-27 KV 9.25 5.50 9.25

Table 5. Recommended Electrical Clearances for PDA Sensor Installation

Note: Clearances are for bare conductors to ground.

2. Determine an acceptable location to mount the BNC terminal box. The location should
be accessible when the unit is on-line and should not require scaffolding or a ladder to
be accessed.

The BNC terminal box may be mounted in the exciter housing or in an auxiliary
enclosure but should not be near any unshielded high voltage sources or switching
circuits to avoid possible electrical interference.

3. Drill five (5) holes in the enclosure for mounting the PDA sensor per figure 9 and
drawing 194D8491 or 194D8492.

NOTE

If the PDA sensors are to be installed on a hydrogen-

cooled bus duct, then a sealant such GE RTV162
Electric Grade Silicone Rubber Adhesive Sealant must
be applied to seal the mating surface (See Figure 7).

4. Mount the PDA sensor. Torque the bolts to 200 inch-pounds, and then turn up corners
of locking plates. The PDA sensor leads should exit through the center hole shown in
Figure 9.

13 of 21
DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

Figure 9. PDA Sensor Base

14 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

5. Connect the high voltage side of the sensor to the iso-phase bus or to the high voltage
bushing connectors using the provided flexible braided bare stranded wire with a
terminal lug connected to each end. The conductor size is equivalent to AWG #14.
Drill and tap a 10-32 hole in the bus bar where the high voltage lead will be connected.
Use a non-magnetic 10-32 screw to secure the flexible braided wire from the top of the
sensor to the bus bar. The high voltage lead should be installed so that the lead is not
under tension, but slack is minimized. The shrink tubing supplied with the kit should be
used over the crimped end of the terminal lug connection and should extend to 1
on to flexible braided cable on both ends of the braided cable.

NOTE

All hardware used to mount the high voltage lead must

be non-magnetic.

3/8-16X1 SS Hex Bolt Sensor Mount Bolt 200 lb. In. 22.6 N-m.
S
M6x10mm Conn. Box ground screw 50 lb. In. 5.6 N-m.

10-32 SS lock nut Sensor HV conn. 30 lb. in. 3.4 N-m.

10-32 Brass Acorn nut HV corona suppressor 25 lb. in. 2.8 N-m.

Table 6. Recommended torque values for threaded fasteners supplied with the sensor.

15 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

C. COAXIAL CABLE CONNECTIONS

The high frequency current transformer (HFCT) outputs exit the base of the coupler as a
black lead and a white lead with crimp connectors. These leads must be attached to the
connection box terminal block during assembly, as shown in figure 11.

The supplied cables have one BNC connector attached. This should be used at the blue
terminal box end. The other end of the cable should be inserted through the gland of the
sensor connection box and stripped 1 to 2 inches. Separate the shield from the center
conductor and twist the shield. The supplied heat shrink tubing should be applied with the
smaller diameter piece on the shield and the larger covering the joint of shield, center
conductor, and outer insulation. Strip center conductor and crimp snap spade terminals
on center conductor and shield. Connect center conductor to white wire of sensor and
shield to black.

The output lead tagged with white shrink tubing or a positive polarity label should be
connected to the same terminal as the center pin of the BNC bulkhead connector and the
remaining lead should be connected as the shield (see figure 11). Note that the coaxial
cable must remain ungrounded. The coaxial HFCT signal cable can be routed to the BNC
terminal box via cable tray or cable straps.

NOTE

The length of the co-axial cable from each PD sensor to

the terminal box should be approximately the same. It is
recommended that the cable length from sensor to
terminal box be 20 feet or less, however this distance
can be increased up to 75 feet as required.

D. GROUND CONNECTIONS

The PDA sensor has a 6 green ground wire extending from the bottom of the sensor. The
green wire must be terminated to the grounding screw, which is found inside the connector
box (see figure 11). An additional ground wire is required to ground the connector box to a
station ground point. This ground wire must be at least 12 AWG. and of a size that will
result in less than one tenth of an ohm resistance from the box to the grounding point for
runs over 50. The ground must meet these specifications or conform to more stringent
local practices.

CAUTION

Failure to properly ground the PD sensor or

connector box will cause the sensor or
connection box ground terminal to go to
generator terminal voltage

16 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

E. TERMINAL BOX CONNECTIONS

Locate the BNC terminal box at a location that meets the previously outlined criteria using
standard mounting practice. It is expected that this mounting procedure will vary
considerably with site-specific space availability, etc. Pull in and connect the RG58 A/U
cable at the PDA sensor end and at the BNC terminal box end.

Figure 10. BNC Connections and Terminal Box

Remove the white bulkhead and connect the phase 1 sensor to PD-1, the phase 2 sensor
to PD-2, and the phase 3 sensor to PD-3 (see Figure 10). Re-install the white bulkhead
and close the BNC terminal box. The terminal box should remain closed when data is not
be acquired from the PD sensors. Figure 11 shows a representative completed PDA
sensor installation.

17 of 21
DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

Figure 11. Sensor Bulkhead Box

18 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

III. MAINTENANCE

Before Each Use

1. Measure voltage to building ground from,

a. Blue BNC terminal box with cover on.
b. BNC connector cap for all 3 phases.
2. Measure voltage across each BNC connector, center conductor to shield.
3. All voltages should measure less than 10 VAC. If voltages greater than
10VAC are detected, the terminal box should be placed out of service until the
generator is offline and the connections can be verified.

Scheduled Maintenance

It is recommended that the following maintenance be performed on an annual

basis. If the unit is operated in such a manner that annual maintenance is not
achievable, the maintenance interval may be extended to two years.

1. Visual Inspection perform a visual inspection of all components for sign

of wear or damage, such as chipping, cracking or fraying. Replace any
damaged components prior to returning the sensor to service.
2. Clean arc suppression surface of PDA coupler with clean lint free cloth or
wiper.
3. Inspect the rubber gasket or the RTV sealant on the Sensor Bulkhead
box if the PDA sensors are installed on a Hydrogen Cooled Generator
(see Figure 7).

Electrical Testing

DC Hipot Test

It is recommended that a DC hipot test be performed on the PD sensors

at every generator major inspection. The sensors should be
disconnected from the high voltage bus prior to testing. It is
recommended that the sensors be tested at a minimum DC voltage of
2E. The maximum hipot test voltage is listed in tables 1 and 2. The
sensors must be tested at hipot voltage for one minute.

19 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

Capacitance Test

The sensor must be disconnected from the high voltage bus while this
test is being performed. The PDA sensors have two capacitors in series
to provide redundancy against a failure to ground. Measuring the
capacitance of the sensor will determine if either one of these capacitors
has failed. The overall capacitance of the sensor should be measured
from the high voltage connection lug to the ground output of the sensor.
The nominal capacitance of the sensor is 900 and 1000 pF, depending
on the coupler rating. If the capacitance of a sensor is tested at less than
800 pF or greater than 1100 pF, the sensor should be removed from
service. This testing should be performed on a 1-2 year cycle,
concurrent with the scheduled maintenance listed above.

IV. MARKING/ESSENTIAL REQUIREMENTS

a. Ta Thermal Rating (ambient)

i. Sensor Ta 1C - 105 C
ii. Boxes Ta 1C - 105 C
iii. Coax Ta -70 C - 200 C

b. Marking Sensor & Boxes: EEx nA IIC 105C X

c. Explosive Atmosphere Seal: For operation in an explosive atmosphere seal

the sensor bulkhead feed-through per Fig. 7 in the PDA Sensor Installation
Instructions.

d. High Voltage Output Safety Procedure requires following Maintenance Section

instructions IIIA before each use.

To receive information about partial discharge testing options or information about PD

monitoring equipment contact GE I&LES via your local GE service representative.

20 of 21
 DWG NO 385A3330 Rev C PDA Hardware Installation Instructions

APPENDIX A INSTALLATION DRAWINGS

194D8491 PDA SENSOR 20KV

194D8492 PDA SENSOR 27KV

132E4225 PDA EQUIPMENT INSTALL

21 of 21