1-Life Cycle Analysis

PT.
VOLTA TERAWINDO BHUWANA
Generator analyzing by “GENERATOR SCORING INDEX”

Is useful to analysis the whole generator healthy condition offer
accurate recommendation action to improvement the machine
quality to extend machine life
PT. VOLTA TERAWINDO BHUWANA
Issued Date Doc.Code
Siswanto May 30, 2018 ITP – 07-0515-R1
Specialist Engineer Revision 1 Page(s) 1 of 41
LIFE CYCLE ANALYSIS OF GENERATOR
1. GENERAL OVERVIEW
1.1. Purpose
This life cycle analysis is a guidance outline the “Industry Best Practice” to analysis of the Insulation
Electrical Machinery approach relies on planned inspections, testing, analyzing and trending of the
relevant equipment parameters by using SCORING modeling.
The information contained within this document are general guidelines techniques in this effort of
extending the life of existing equipment, involving life cycle assessment and condition evaluation of
electrical rotating machine. This document consists of methodology involving assessment technique
for electrical rotating machine, scope of work, various requirements for assessment and time
involvement.
The condition assessment methodology outlined in this document applies to turbo and hydroelectric
generators, motor/generators, and HV motors.
The following indicators are used to separately evaluate the condition of the stator and rotor:
Physical Inspection
NDT inspection for mechanical parts, i.e: Retaining rings, rotor fans, journal bearings, etc
Insulation Resistance and Polarization Index (stator and field windings)
PDCA - Polarization Depolarization Current Analysis (stator and field winding)
RSO – Recurrent Surge Oscillosgraph apply for field winding only
AC Impedance, apply for field winding only
FDS - Frequency Domain Spectroscopy, as function Non Linear Behavior (stator only)
Dissipation Power Factor (Tip-up) Analysis (stator only)
Contact coefficient (stator only)
Partial Discharge Phenomenon (stator only)
Core Imperfection Analysis – ELCID (stator only)
Core tightness Inspection (stator only)
Wedge Tightening Analysis (stator only)
DC leakage test, NOT recommended since this test is destructive, when customer required
this test all the risk is customer responsibility, i.e: insulation breakdown
Operation & Maintenance History
Age
The main objective of this assessment will be to generate a report which gives the information to
achieve following tasks
To arrest the deterioration in performance
To improve the availability, reliability, efficiency and safety of equipment.
To regain lost capacity
To extend useful life beyond design life and save investment on new equipment.
ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 1

1.2. Background
Failure of insulation is considered to be major factor in electrical rotating machine. Aging of insulation
generally follows a chemical rate degradation curve and in addition is severely affected by the
number of stops and starts, the frequency of stops and starts as well as large load variations.
Wound stator / rotor windings operating in utility and industrial plants have failed when exposed to the
fast rise-time voltage surges coming from unbalance load, drives, breaker, lightning impulse, etc.
Machine failure is due to a combination of bad luck in winding insulation process and material quality
show that these surges create partial discharges (also called corona) and these discharges may
eventually destroy the turn-to-turn and/or phase-to-phase insulation, resulting in premature machine
failure.
The fast rise-time voltage surges can lead to an electrical breakdown of the turn insulation in motors /
generators stator windings . If the turn insulation is of an insufficient thickness, or has aged in service,
the insulation will puncture when a short rise-time voltage surge occurs. Punctured turn insulation
allows for a very high circulating current to flow into the affected copper turn, rapidly melting the
copper conductors, which, in turn, results in a consequent burning/melting of the slot liner insulation,
thus leading to a stator winding ground fault.
2. Condition Indicator
2.1. Condition Assessment Methodology.
The condition assessment methodology consists of analyzing each condition indicator individually to
arrive at a condition indicator score. The scores are weighted and summed to determine the
Condition Index. Condition Index are developed separately for the stator and rotor. The lower of the
Stator and Rotor Condition Index is used to arrive at an overall Generator Condition Index. The
Generator Condition Index is applied to the Generator Condition-Based Alternatives, Table 1, to
determine the recommended course of action.
The stator condition assessment focuses on the stator winding and core. Stator winding condition is
evaluated using Tier 1 and Tier 2 tests. Assessment of the stator core is considered to be non-
routine, and therefore, a Tier 2 evaluation.
Rotor condition assessment comprises the rotor winding, amortisseur (for hydroelectric), retaining
rings (for turbo generator). Rotor components are evaluated using both Tier 1 and Tier 2 tests.
Reasonable efforts should be made to perform Tier 1 inspections, tests, and measurements.
However, when data is unavailable to properly score a condition indicator, it may be assumed that the
score is “Good” or numerically equal to some mid-range number such as 2. This strategy must
be used judiciously to prevent erroneous results and conclusions. In recognition of the potential
impact of poor or missing data, a separate Data Quality Indicator is rated as a means of evaluating
and recording confidence in the final Generator Condition Index.

2.2. SCORING
Condition indicator scoring is somewhat subjective, relying on the experience and opinions of plant
staff and generator experts. Relative terms such as “Results Normal” and “Degradation” refer to
results that are compared to industry accepted levels; or to baseline or previously acceptable levels
on this equipment; or to equipment of similar design, construction, or age operating in a similar
environment.
2.3. WEIGHTING FACTORS

Weighting factors used in the condition assessment methodology recognize that some Condition
Indicators affect the Generator Condition Index to a greater or lesser degree than other indicators.
3. TESTING TIER 1. STATOR
These condition indicators are initially evaluated using Tier 1 inspections, tests, and measurements,
which are conducted by a part of routine maintenance activities. Numerical scores are assigned to
each stator and rotor condition indicator, which are then weighted and summed to determine the
Stator and Rotor Condition Index. The lower of the two index is selected to represent the overall
Generator Condition Index.
3.1. Stator Condition Indicator
3.1.1. Stator Condition Indicator 1 – Operation & Maintenance History
During operation, large synchronous generators are continuously subjected to electrical, mechanical,
thermal, and environmental stresses. These stresses act and interact in complex ways to degrade the
machine’s components and reduce its useful life. Deterioration of the stator winding insulation is a
leading factor for determining the serviceability of generators. Unexpected stator winding failure can
result in forced outages and costly emergency repairs.
Operation and maintenance history may provide a useful indication of stator condition. The operation
and maintenance history of the generator to make a subjective determination of scoring that
encompasses as many operation and maintenance factors as possible under this indicator. Factors to
consider include:
Maintenance history
Frequent starts and stops
Rapid loading ramp rates are used
Operating outside of voltage rating (either higher or lower)
Sustained overloading
Frequent rough-zone crossings
Close-in lightning strikes
Out-of-phase breaker closings

Unbalanced phase operation

Previous failures on this equipment related to the stator winding or core
Results of stator winding O & M history are analyzed and applied to Table 1 to arrive at an
appropriate Stator Condition Indicator Score
TIER 1. TABLE 1 – STATOR WINDING OPERATION & MAINTENANCE HISTORY SCORING

Stator Condition
RESULT
Indicator Score.
Operational and maintenance normal
Some abnormal operating conditions experienced and or additional
maintenance above normal occurring
Significant operation outside normal and or significant additional
maintenance is required: forced outage occurs, outages are regularly extend
due to maintenance problems, similar units are problematic
Repeated forced outages, maintenance not cost effective, major electrical or
mechanical failures, similar units have reached end-of-life
3.1.2. Stator Condition Indicator 2 – Physical Inspection

Several types of stator winding problems can be detected during the course of physical inspections,
such as insulation cracks, bulging or puffy coils, surface corona, contamination, carbon tracks,
winding movement, loose bracing and blocking, and loose wedges or slot fillers.
Determination of scoring that encompasses as many inspection factors as possible under this
indicator.
Negligible evidence of aging, damage, and/or deterioration would lead to a “normal” rating, whereas a
minor amount of wear and tear would be rated as “some deterioration.” If the deterioration observed
is very obvious and widespread, a rating of “significant deterioration” is appropriate. At a minimum,
the following areas should be inspected and the condition evaluated:
Stator winding.
Stator winding wedges, packing, blocking, and bracing
Circuit ring bus
Main and neutral leads.
Results of the stator winding physical inspection are analyzed and applied to Table 2 to arrive at a
Stator Condition Indicator Score.

TIER 1. Table 2 – Stator Winding Physical Inspection Scoring

Stator Condition
Results
Indicator Score
Inspection results are normal.
Inspection shows some deterioration.
Inspection shows significant deterioration.
Inspection shows complete or imminent failure of stator winding components.
3.1.3. Insulation Resistance and Polarization Index
Insulation resistance is defined as the quotient of the applied direct voltage over the measured
current (R = V/I). For a high capacitance specimen such as a generator stator winding, an applied
voltage step will result in a measured current that decays exponentially with time.
Because of this time-dependency, insulation resistance is normally calculated and recorded one
minute after the test voltage is applied. Insulation resistance measurements combine both surface
and volume resistances, and are mainly used to detect moisture absorption, conductive
contamination, degree of cure, and cracks or fissures. Insulation resistance tests are sensitive to
specimen temperature and are often normalized to a standard temperature (typically 40°C) for
analysis. Humidity and surface contamination can also affect the measurement. The insulation
resistance of good insulation may range from hundreds to thousands of megaohms.
Comparison of individual phases and trending over time are the best means of evaluating insulation
condition.
A polarization index test is similar to the insulation resistance test except that current readings are
taken at two time intervals, normally one and ten minutes after application of the voltage step. The
quotient of these two current readings (I1/I10) is termed the polarization index and gives an indication
of insulation dryness, contamination, cure, and mechanical integrity.
Since the polarization index is the ratio of two measurements made under identical conditions, it is
less sensitive to temperature variations than is insulation resistance. However, normal polarization
index vary significantly for different types of insulation systems depending on the electrical properties
of the constituent dielectric materials, making it difficult to define acceptable polarization index criteria.
Therefore, trending of measurements over time and comparison between phases are typically
necessary to assess insulation condition.

TIER 1. Table 3 – Stator Winding Insulation Resistance and Polarization Index Scoring
Stator Condition
Results
Indicator Score
Results are normal and similar to previous tests
Results indicate minor decrease in insulation resistance or polarization index (e.g., factor
of 2 decrease)
Results indicate significant decrease in insulation resistance or polarization index (e.g.,
factor of 10 decrease)
Insulation resistance or polarization index is below minimum acceptable values
3.1.4. Winding DC Resistance
During this test, the measurement of the ohmic value between terminals winding for the winding
installed or between conductor lead for individual coil, is carried out. Given the relatively low series dc
resistance of winding.
The purpose of this test is to detect shorted turns, bad connections, wrong connection and open
circuit. Acceptable test result consist of three resistance value each phase to be balanced (for
installed winding) and balance between coils (for individual coil test), The machine should be in room
temperature when the test is performed.
The resistance should be corrected to temperature:
Rt2 (t1  k) When the resistance, Rt2 : of a winding has been determined by test at winding
Rt1  temperature,
(t2  k)
t1 : the resistance may be corrected to a specified temperature,
t2 : the temperature test of winding
k : is 234.5 for 100% IACS conductivity copper, or 225 for aluminum, based on a volume
conductivity of 62%
TIER 1. Table 4 – Stator Winding DC Resistance Index Scoring

Stator Condition Indicator
Results
Score
Results are normal balance deviation <2%between phase or
manufacture measurement at the same temperature reference
Results indicate minor deviation <5%between phase or manufacture
measurement at the same temperature reference
Results indicate significant deviation ≤10% between phase or
Results indicate extremely deviation >10% between phase or

3.1.5. Stator Condition Indicator 4 – Winding Age
The age of the generator stator winding is an important factor to consider when identifying candidates
for replacement. Age is one indicator of remaining life and upgrade potential to state-of-the-art
materials and designs. The design life of a stator winding rated 6.9 kV or higher is typically 25 to 35
years. For lower voltage windings, the design life is typically 35 years or more. It is important to
recognize, however, that although age may be a useful indicator, the actual service life that can be
realized varies widely depending on the specific equipment manufacturer and date of manufacture;
the insulation system design, materials, and production methods; the quality of installation; and the
generator’s operation and maintenance history.
TIER 1. Table 5 – Stator Winding Age Index Scoring

Results Stator Condition Indicator Score
< 20 years
≥ 20 and < 30 years
≥ 40
3.1.6. TIER 1 – STATOR CONDITION INDEX CALCULATIONS

Enter the stator condition indicator scores from the tables above into the Stator Condition
Assessment Summary form at the end of this document. Multiply each stator indicator score by its
respective Weighting Factor, and sum the Total Scores to arrive at the Tier 1 Stator Condition Index.
Calculation the Tier 1 Stator Condition Index
TIER 1. Generator Stator Condition Summary

(For instructions on indicator scoring, please refer to condition assessment guide)
No Condition Indicator Score × Weighting Factor = Total Score
O & M History
1
(Score must be 0, 1, 2, or 3)
Physical Inspection
2
Insulation Resistance and Polarization Index
3
Winding DC Resistance
4
Winding Age
5
Tier 1 Stator Condition Index
(Sum of individual Total Scores)
(Condition Index should be between 0 and 10)

3.1.7 TIER 1 – STATOR DATA QUALITY INDICATOR

The Stator Data Quality Indicator reflects the quality of the inspection, test and measurement results
used to evaluate the stator condition under Tier 1. The more current and complete the results are, the
higher the rating for this indicator. The normal testing frequency is defined as the organization’s
recommended frequency for performing the specific test or inspection.
TABLE 6. STATOR DATA QUALITY SCORING

Stator Data Quality
Results
Indicator Score
All Tier 1 inspections, tests and measurements were completed within the normal
10
testing frequency and the results are reliable.
One or more of the Tier 1 inspections, tests and measurements were Completed ≥ 6
7
and < 24 months past the normal testing frequency and results are reliable.
One or more of the Tier 1 inspections, tests and measurements were completed ≥ 24
and < 36 months past the normal testing frequency, or some of the results are not 4
available or are of questionable integrity.
months past the normal frequency, or no results are available or many are of 0
questionable integrity.
Tier 1 Stator Data Quality Indicator

(Value must be 0, 4, 7, or 10)
SUMMARY TIER 1 . STATOR

To determine the Tier 1 Generator Stator Condition Index (Value should be between 0 and 10),
choose the lower of the Tier 1 Stator Condition Index and Record the Data Quality Indicator
associated with the chosen Condition Index
Generator Condition Index Stator _______________

Data Quality Indicator Stator ________________

3.2. TEST TIER 1 : ROTOR
3.2.1. Rotor Condition Indicator 1 – Operation & Maintenance History
Operation and maintenance history may provide a useful indication of generator rotor condition. The
operation and maintenance history of the rotor should be reviewed by qualified personnel to make a
subjective determination of scoring that encompasses as many operation and maintenance factors as
possible under this indicator. Factors to consider include:
Maintenance needs increasing with time or problems are re-occurring.

Spare parts are becoming unavailable.
Operating outside of voltage rating (either higher or lower).
Sustained overloading.
Frequent rough-zone crossings.
Out-of-phase breaker closings.
Number of times unit has been subjected to over speed or runaway (usually associated with
load rejection).
Previous failures on this equipment related to the rotor or field winding.
Failures or problems on equipment of similar design, construction, or age operating in a
similar environment.
TIER 1. Table 7 – Rotor Operation & Maintenance History Index Scoring

Rotor Condition Indicator
Results
Score
Operation and maintenance normal
Some abnormal operating conditions experienced and/or additional
maintenance above normal is required.
Significant operation outside normal and/or significant additional
maintenance is required; forced outage occurs; outages are
regularly extended due to maintenance problems; similar units are
problematic
Repeated forced outages. maintenance not cost effective; major
electrical or mechanical failures, similar units have reached end-of-
life.

3.2.2. Rotor Condition Indicator 2 – Physical Inspection

Several types of rotor problems can be detected during the course of physical inspections, such as
overheating, loose and vibrating components, impact damage, and contamination, a subjective
determination of scoring that encompasses as many inspection factors as possible under this
indicator. The following areas should be inspected and the deterioration should be evaluated:
Rotor Turbo Generator

Retaining Rings condition, such as: electric discharge, SCC (stress corrosion crack)
Steel wedge migration to RR
Centering ring condition
Centering fan and fan blades
Steel wedge electric discharge, fretting due to negative sequence current
Axial lead connection
Pole connections.
Coil blocking movement
Ventilating duct blocking
Slipring conditions, such as: corrosion, ovalities, hair liner.
Carbon brushes and springs condition
Carbon holder condition such as: overheating, melting,
Rotating diodes and fuses (for brushless)
Rotor Hydroelectric Generator

Rotor hub, radial arms, and rim.
Field poles, keys, collars, and pole faces.
Field windings and interpole connections.
Field winding leads.
Amortisseur winding bars, shorting straps, and inter-connections.
Rim-mounted fan blades
TIER 1. Table 8 – Rotor Physical Inspection Index Scoring

Results Rotor Condition Indicator Score
Inspection results are normal
Inspection shows some deterioration.
Inspection shows significant deterioration.
Inspection shows complete or imminent failure of field winding
components.

3.2.3. Rotor Condition Indicator 3 – Insulation Resistance and Polarization Index
Refer to “Stator Condition Indicator 3 – Insulation Resistance and Polarization Index” in section
3.4.1.3. above for a detailed description of insulation resistance and polarization index
measurements.
TIER 1. Table 9 – Rotor Winding Insulation Resistance and Polarization Index Scoring
Results are normal and similar to previous tests
Results indicate minor decrease in insulation resistance or polarization
index (e.g., factor of 2 decrease)
Results indicate significant decrease in insulation resistance or
polarization index (e.g., factor of 10 decrease)
Insulation resistance or polarization index is below minimum acceptable
values
3.2.4. Rotor Condition Indicator 4. Rotor Winding DC Resistance
Refer to “Stator Condition Indicator 4 – Stator Winding DC Resistance Index” in section 3.4.1.4.
above for a detailed description of Winding DC Resistance Index measurements.
TIER 1. Table 10 – Rotor Winding DC Resistance Index Scoring

Results are normal balance deviation <2%between pole or manufacture
Results indicate minor deviation <5%between pole or manufacture
Results indicate significant deviation ≤10% between pole or
Results indicate extremely deviation >10% between pole or

3.2.5. Rotor Condition Indicator 5 – Winding Age
TIER 1. Table 11 – Rotor Winding Age Index Scoring

< 20 years
≥ 40
3.2.6. TIER 1 – ROTOR CONDITION INDEX CALCULATIONS

Enter the rotor condition indicator scores from the tables above into the Rotor Condition Assessment
Summary form at the end of this document. Multiply each stator indicator score by its respective
Weighting Factor, and sum the Total Scores to arrive at the Tier 1 Rotor Condition Index.
Calculation the Tier 1 Rotor Condition Index
TIER 1. Generator Rotor Condition Summary

(For instructions on indicator scoring, please refer to condition assessment guide)
No Condition Indicator Score × Weighting Factor = Total Score
O & M History
1
Physical Inspection
2
Insulation Resistance and Polarization Index
3
Winding DC Resistance
4
Winding Age
5
Tier 1 Rotor Condition Index
(Sum of individual Total Scores)
(Condition Index should be between 0 and 10)

3.2.6.1. TIER 1 – ROTOR DATA QUALITY INDICATOR
The Rotor Data Quality Indicator reflects the quality of the inspection, test and measurement results
used to evaluate the rotor condition under Tier 1. The more current and complete the results are, the
higher the rating for this indicator. The normal testing frequency is defined as the organization’s
recommended frequency for performing the specific test or inspection.
TABLE 12. TIER-1 ROTOR DATA QUALITY SCORING

Stator Data Quality
Results
Indicator Score
All Tier 1 inspections, tests and measurements were completed within the
10
normal testing frequency and the results are reliable.
One or more of the Tier 1 inspections, tests and measurements were
Completed ≥ 6 and < 24 months past the normal testing frequency and 7
results are reliable.
completed ≥ 24 and < 36 months past the normal testing frequency, or some 4
of the results are not available or are of questionable integrity.
completed ≥ 36 months past the normal frequency, or no results are available 0
or many are of questionable integrity.
Tier 1 Rotor Data Quality Indicator

SUMMARY TIER 1 . ROTOR

To determine the Tier 1 Generator Rotor Condition Index (Value should be between 0 and 10),
choose the lower of the Tier 1 Rotor Condition Index and Record the Data Quality Indicator
associated with the chosen Condition Index
Generator Condition Index Rotor _______________

Data Quality Indicator Rotor ________________

4. TIER 2 – STATOR INSPECTIONS, TESTS, AND MEASUREMENTS

Tier 2 inspections, tests, and measurements generally require specialized equipment or expertise,
may be intrusive, or may require an outage to perform. A Tier 2 assessment is not considered routine.
Tier 2 inspections are intended to affect the Generator Stator Condition Index established using Tier 1
tests as well as confirm or disprove the need for more extensive maintenance, rehabilitation, or
generator replacement
4.1. TIER 2. STATOR
4.1.1. TIER2. Stator Condition Indicator 1. Dissipation (or Power) Factor Measurements
The dissipation factor, or tan δ, represents the losses in an insulation tested under sinusoidal voltage
conditions. Absolute values of tan δ as well as changes with respect to voltage are used to assess
insulation quality and condition. When performing the test, several tan δ measurements are made
over a range of applied voltages. For example, a typical test schedule would involve making
measurements from 0.20 Un (where Un equals the rated phase-to-neutral voltage of the winding)
through 1.20 Un, increasing the test voltage in increments of 0.20 Un. The tip-up, or Δ tan δ, is
calculated by subtracting tan δ measured at 0.20 Un from tan δ at 1.0 Un. Relatively high values of
tan δ and tip-up generally indicate the presence of voids, delaminations, or high conductivity.
Normal tan δ measurements may vary depending on several factors, such as the type of dielectric
materials comprising the insulation, the effect of the end winding voltage stress grading treatment,
and specimen temperature and humidity. Given the difficulty in establishing absolute limits for
tan δ measurements, trending over time and/or comparisons among identical machines are
generally needed to analyze and interpret dissipation factor values.
TIER 2. Table 13 – Stator Tan∂ Index Scoring

Tan δ and tip-up are below expected values
Tan δ and tip-up are equal to expected values
Tan δ or tip-up slightly exceed expected values.
Tan δ or tip-up somewhat exceed expected values or have
increased since previous test
Tan δ or tip-up significantly exceed expected values or have
increased sharply since previous test.

4.1.2. TIER 2. Stator Condition Indicator 2. High-Potential Withstand Test
High-potential withstand tests are typically performed to provide some assurance that the winding
insulation has a minimum level of electrical strength. Because the inherent withstand capability of
sound insulation is well above the usual proof test value, failure during a test at an appropriate
voltage indicates the insulation is unsuitable for service. Withstand tests are intended to search for
flaws in the material and for manufacturing defects, and to demonstrate in a practical manner that the
insulation has a minimum level of electrical integrity. A primary requirement of such a test is that it
should be discerning and effective in detecting serious flaws at or below the minimum specified
strength without damaging sound insulation. The applied test voltage may be power frequency, very
low frequency (VLF), or direct voltage.
TIER 2. Table 14 – Stator High-Potential Withstand Test Index Scoring

Passed withstand test
Failed withstand test.
4.1.3. TIER 2. Stator Condition Indicator 3. Ramped Voltage Test

To conduct this test, an automatic high-voltage power supply (i.e., ramped voltage test set) is used to
linearly increase the applied direct voltage from zero up to some maximum value at a constant ramp
rate, typically 1 to 2 kV per minute. The current response versus applied voltage is measured and
plotted, and the results are used to evaluate the condition of the insulation by noting deviations from
the normal shape of the test curve. Any departure from a smooth curve could be an indication of
insulation problems. Because the maximum test voltage is above the normal operating stress, the
ramped voltage test also serves as a high-potential withstand test.
TIER 2. Table 15 – Stator Ramped Voltage Index Scoring

Smooth, linear curve.
Curve slightly nonlinear, similar to previous test results.*
Curve less linear than previous test results.*
Curve significantly less linear than previous test results.*
Test stopped early to avoid breakdown
Failure during test

4.1.4. TIER 2. Stator Condition Indicator 4. Partial Discharge Phenomenon
Partial discharges are localized ionizations of the gaseous space surrounding or within a solid
insulation. When the electric stress in the gas exceeds a critical value, a transient ionization, or partial
discharge, occurs. The ionized gas contains electrons, ions, excited molecules, and free radicals.
These chemically reactive species can affect and degrade the adjacent solid insulation. Although the
damage caused by a single partial discharge (PD) event is minute, the cumulative effect of many
discharges can eventually lead to insulation failure.
There are several potential sites of partial discharges in high-voltage generator stator windings, such
as between the surface of the slot portion of the winding and the grounded stator core, at either
boundary of the voltage stress grading coating in the end turn area, in the winding overhang region
where potential differences exist between adjacent coils separated by small air spaces, and internal
to the insulation within voids, delaminations, or other defects.
PD measuring equipment and data analysis methods have been developed to quantify the level of
discharge activity and determine the source. Measurements may be made either on-line or offline,
and a variety of detection techniques are possible (e.g., corona probe, PDA,). Since discharge
measurements are greatly influenced by the specific measuring technique, the PD instrument
manufacturer should be consulted to determine appropriate evaluation criteria.
TIER 2. Table 16 – Stator Partial Discharge Phenomenon Index Scoring

Low PD readings throughout the generator
Few in number and low in magnitude
Numerous high PD readings
Widespread and abnormally high PD readings
4.1.5. TIER 2. Stator Condition Indicator 5. Core Imperfection Analysis – ELCID
The Electromagnetic Core Imperfection Detector (EL CID) test is used to detect and evaluate known
or suspected damage to the stator core lamination insulation. The main advantage of the EL CID test
over the rated flux test is that it requires a much smaller capacity power supply for the excitation
winding, since only 3 to 4 percent of rated flux needs to be induced in the core.
The EL CID test operates on the basis that eddy currents will flow through failed or significantly aged
core insulation. Using a special “Chattock coil,” a voltage signal is obtained that is proportional to the
magnitude of eddy current flowing between laminations. The measured voltage is fed to a signal
processor what gives an output in mA (milliamperes) that represents the axial component of the
measured voltage. Relatively high readings indicate faulty insulation.
ELCID trace identified in general, the quadrature fault over 100 mA, from an average baseline
would cause concerns and require further investigations,
100mA peak quad current is equal 5-10 Deg Celsius rise from the rest of core temperature.

ELCID Value Indication of Core Condition

Not greater than 100 mA Acceptable
100 – 200 mA A possible problem, monitor periodically
200 – 300 mA Monitor regularly for a potential problem
Above 300 mA Significant deterioration is likely
TIER 2. Table 17 – Stator Core Imperfection ELCID Index Scoring

No readings > 50 mA
No readings > 100 mA
One reading > 100 mA and ≤ 200 mA
Two or more readings > 100 mA and ≤ 200 mA
One or more readings > 200 mA
4.1.6. TIER 2. Stator Condition Indicator 6. PDCA - Polarization Depolarization Current

Analysis
The PDC-Analysis is a non-destructive method for determining the moisture content in the solid
insulation material like paper, “NO STANDARD ARE AVAILABLE FOR JUDGMENT” PDC and Non
Linear are normally use to test for transformer to identify the conduction due to free water in the
transformer oil, by charging DC voltage, the current charging during a certain time (Tp) so called
“polarization duration” and the current charging is called “polarization current”, After elapsing the
polarisation duration, power supply to be switched off, power supply goes into the other position and
the dielectric is short circuited via the ammeter. Thus, the discharging current jumps to a negative
value, which goes gradually towards zero. Both kinds of currents called relaxation currents
Polarization
The main measurement results include polarisation currents and depolarisation currents in time
domain and they are in log-log scales. The polarisation currents consist of absorption currents due to
polarisation phenomena : (e.g. aging molecules at the dielectric interface caused by oxidation or heat,
mixture of spilled lubricating oil and dust, by-products of partial discharges, corrosive contaminants
from chemical plants, sea salt or hydrogen sulphide, etc.) plus conduction currents due to conduction
phenomena (mostly moisture) plus, in some cases , surface leakage currents (due to conductive
contaminants e.g. free water, carbon dust, metal debris, etc.).
The depolarisation currents

The absorption currents over serviced years increase due to aging of dielectric which bonds the mica
together (e.g. resin, varnish, etc.), oxidation aging and thermal aging.
Absorption currents may decrease due to formation of voids or gap due to delamination.
While conductive contaminants increase only the polarisation currents but not the depolarisation
currents moisture in the stator insulation raises the whole polarisation and depolarisation currents.

TIER 2. Table 18 – Stator PDC Index Scoring

Dispersion Ratio & Charge Storage Tan δ are below expected
values
Dispersion Ratio & Charge Storage Tan δ are equal to expected
values
Dispersion Ratio & Charge Storage Tan δ are slightly exceed
expected values.
Dispersion Ratio & Charge Storage Tan δ are somewhat exceed
expected values or have increased since previous test
Dispersion Ratio & Charge Storage Tan δ are significantly exceed
expected values or have increased sharply since previous test.
4.1.7. TIER 2. Stator Condition Indicator 7. FDS - Frequency Domain Spectroscopy, as

function Non Linear Behavior
The Frequency Domain Spectroscopy test (FDS) is similar to the frequency used power factor
measurement, except that is multiple frequencies. The advantage of this test at the multiple frequency
that is much more information which makes it possible to distinguish properties of Insulation paper.
FDS analysis of an insulation systems can give indication of the condition of the insulation system
such as a direct reading of the moisture content and detection of the presence of contamination.
Since the effect of moisture and the abnormalities on the dielectric properties of the insulation
systems more pronounce a specific frequency range, the preferred measurement is done at a very
broad frequency range, such as 0.001 – 1000 Hz. The dielectric properties evaluated are the real and
imaginary capacitance ( or permittivity) and the dissipation insulation system model, humidity content
and oil conductivity can be estimated
FDS or Non Linear of the insulation is attributed mainly to the slot-end/endwinding regions due to the
harmonic content of all three phases.
Large amount of harmonic content (tan∂) at higher-order frequencies (10th –16th) and middle-order
frequencies (4th – 6th), is indicates high ionic activity in the slot region. This could be due to presence
of partial discharges.
The most likely cause for the FDS or non-linear behaviour is:
Lack of contact of coil with core or coil/wedge looseness.
Modification of anti-corona shield.
Partial discharges, in slot end or end-winding region

TIER 2. Table 19 – Stator FDS-Non Linear Index Scoring

Harmonic content of Tan δ are below expected values
Dispersion Ratio & Charge Storage Tan δ are equal to expected
values
Harmonic content of Tan δ are slightly exceed expected values.
Harmonic content of Tan δ are somewhat exceed expected values
or have increased since previous test
Harmonic content of Tan δ are significantly exceed expected values
or have increased sharply since previous test.
4.1.8. TIER 2. Stator Condition Indicator 8. Contact Coefficient
To prevent PD on the coil or bar surfaces (also known as slot discharge) between the coil surface and
the stator core, manufacturers have long been coating the coil/bar in the slot area with a partly
conductive coating. The coating is usually a carbonblack-loaded paint or tape. This coating, often
called a semiconductive coating is likely to be in contact with the grounded stator core at many
places along the length of the slot. With a sufficiently low resistance this coating is essentially at
ground potential because of the contact with the core.
Poorly manufactured coatings or abrasion of the coating due to coils and bars being loose in the slot
will reduce the effectiveness of the coating and promote the onset of the slot discharges. As the
semiconductive coating deteriorates, its resistance increases. Also, if the coils are loose in the slot,
there may be only a few points of contact between the semiconductive coating and the core, rather
than many. In both these situations, the contact resistance between the coil surface coating and the
core will increase. In this test, the electrical resistance between the coil surface and the core is
directly measured. The result is that semiconductive coatings with surface resistance from 0.1 to 10
kilohms per square prevent surface discharges in the slot.
The measurement of the resistance between the semiconductive coating and the grounded stator
core can indicate if coils are loose in the slot or if the coating has deteriorated. This test is only useful
in form-wound stator windings that have a semiconductive coating. Thus, the test is usually only
applied to stators rated at 6 kV and above.
TIER 2. Table 20 – Stator FDS-Non Linear Index Scoring

Contact Coefficient Resistance are ≤ 2kΩ
Contact Coefficient Resistance are between 2kΩ - <5kΩ
Contact Coefficient Resistance are between 5kΩ - <10kΩ
Contact Coefficient Resistance are between ≥10kΩ

4.1.9. TIER 2. Stator Condition Indicator 9. Wedge Tightening Analysis
Stator windings are wedged into the core slots and subjected to positive radial pressure to protect the
winding from vibration-induced damage during normal operation and to keep coils/bars from being
forced out of the slots during phase-to-phase short circuit conditions. This evaluation is used to
determine the condition of the stator winding wedge system. The wedge system should be examined
closely for loose, broken, or burnt wedges. To perform a comprehensive assessment with the rotor in
place, one or two pole pieces must be removed in order to access the entire length of the stator core
and the rotor must be rotated manually in order to inspect all wedges in every slot. A partial
evaluation may be conducted by inspecting only those wedges that are within reach between the
rotor poles. The wedge evaluation procedure requires careful visual inspection of the wedging
system, including wedges and slot packing materials.
The wedge system may be further examined by tapping the wedges with a blunt metallic instrument
which rings or vibrates when hit against a solidly wedged slot. Loose wedges produce a dull sound
when tapped. Wedge systems utilizing under-wedge ripple springs may be evaluated using a depth
gauge to measure the ripple spring compression. Regardless of the specific evaluation method used,
wedge system condition is assessed based on the overall percentage of loose wedges as well as the
number and location of loose wedges in any given slot.
Corrective action
Once a chart is made indicating the location of loose wedges, a determination of corrective action can
be made. In general, large machines can tolerate a fewer percentage of loose wedges than smaller
machines.
Several loose wedges adjacent to each other are a more serious condition than if randomly scattered
through the bore or slot. Loose wedges, which are near or at the end of a slot, create a more serious
condition than if located near the center of the core. Wedges that are loose enough to allow filler
strips to migrate out from under them indicates a serious condition and should be corrected in all
cases.
TIER 2. Table 21 – Stator Tightening Wedge Index Scoring

Rewedging completed within last < 5 years and no indication of
loose wedges.
No indication of loose wedges.
Few loose wedges.
Numerous loose wedges.
Widespread loose wedges.

4.1.10. TIER 2. Stator Condition Indicator 10. Core Loop Test

The stator core loop test, also known as the ring test or rated flux test, is performed on motor or
generator stators to evaluate the integrity of the core laminations. Core damage may be caused by
ingress of foreign bodies into the stator bore, excessive vibrations, or deterioration of the lamination
insulation due to overheating or other aging processes. Inadvertent core damage may also occur
during rewedging or removal of the rotor and/or stator coils. A bearing failure may also cause the
rotor to rub and damage the stator core. The core loop test is used to detect damage, assess its
severity, and indicate whether repair is required.
The loop test is made by wrapping an excitation winding around the stator core and frame. A 50-60-
Hz voltage is applied to the winding sufficient to induce a flux approximately equal to the rated
operating flux density and produce normal axial voltage between laminations. Defective areas of the
core or tooth insulation appear as “hot spots’ that can be detected via infrared thermal imaging. An
area of iron exhibiting a temperature equal to or greater than 5 °C above the average core
temperature is generally considered to be a hot spot.
TIER 2. Table 22 – Stator Core Loop Index Scoring

No visible hot spots
One warm spot < 5 °C
Two or more warm spots < 5 °C, or one hot spot ≥ 5 °C and < 10 °C
Two or more hot spots ≥ 5 °C and < 10 °C
One or more hot spots ≥ 10 °C
4.1.11. TIER 2. Stator Condition Indicator 11. Stator Core Inspection

A stator core physical inspection may be done with the rotor in place although it is more convenient to
examine the core with the rotor removed. The stator core should be examined for looseness and
shifting. Core looseness should be checked with the knife test. Stator through bolt torque may also be
checked. Any broken core laminations, laminations which protrude into the air gap, signs of fretting
corrosion, bent core duct separators, or other evidence of core damage should be noted. Interlaminar
insulation faults may result in severe overheating which could damage the stator winding at that
location. Generally, defects at the core surface are easily observed while defects in the slot area or in
the back iron are not detectible visually. If inspection panels are present on the stator frame wrapper,
they should be removed to allow inspection of the back iron and stator frame.
TIER 2. Table 23 – Stator Core Inspection Index Scoring

Core condition appears very good
No indication of core damage or deterioration
Minor core damage or deterioration
Moderate core damage or deterioration
Significant core damage or deterioration

4.1.12. Calculation the Tier 2 Stator Condition Index
TABLE 24. TIER 2 STATOR CONDITION SUMMARY

No TIER 2 TEST STATOR STATOR CONDITION INDEX
Table 13 Stator Tan∂ Index Scoring
Table 14 Stator High-Potential Withstand Test
Table 15 Stator Ramped Voltage Test
Table 16 Stator Partial Discharge Phenomenon
Table 17 Stator Core Imperfection Analysis – ELCID
Table 18 Stator PDCA - Polarization Depolarization Current Analysis
Table 19 Stator FDS - Frequency Domain Spectroscopy, as function
Non Linear Behavior
Table 20 Stator Contact Coefficient
Table 21 Stator Wedge Tightening Analysis
Table 22 Stator Core Loop Test
Table 23 Stator Core Inspection
Tier 2 Adjustments to Stator Condition Index
(Sum of individual Adjustments)
4.1.13. Calculation NET Stator Condition Index
To calculate the Net Stator Condition Index (Value should be between 0 and 10), subtract the Tier 2
Adjustments from the Tier 1 Stator Condition Index:
Net Stator Condition Index = Stator Condition Index Tier 1 – Stator Condition Index Tier 2
Tier 1 Stator Condition Index __________

Tier 2 Stator Condition Index __________
____________________________________
Net Stator Condition Index =

4.1.14. Stator Data Quality Scoring TIER 2
TABLE 25. STATOR DATA QUALITY SCORING TIER 2

Stator Data Quality
Results
Indicator Score
and < 36 months past the normal testing frequency, or some of the results are not
months past the normal frequency, or no results are available or many are of
Tier 1 Stator Data Quality Indicator
4.1.15. Determine the Tier 2 Generator Stator Condition Index
To determine the Net Generator Stator Condition Index (Value should be between 0 and 10), choose
the lower of the Net Stator Condition Index.
Record the Data Quality Indicator associated with the chosen Condition Index:
Net Stator Generator Condition Index _____________
Data Quality Indicator ______________
STATOR GENERATOR CONDITION

STATOR SUGGESTION OF ACTION
INDEX
Continue O & M without restriction. Repeat condition assessment as
≥ 7.0 and ≤ 10 (Good)
needed.
Continue operation but re-evaluate O & M practices Consider using
≥ 3.0 and < 7 (Fair)
appropriate Tier 2 tests. Repeat condition assessment process as
needed.
Immediate evaluation including additional Tier 2 testing. Consultation
≥ 0 and < 3.0 (Poor)
with experts. Adjust O & M as prudent. Begin
replacement/rehabilitation process
.

4.2. TIER 2. ROTOR INSPECTIONS, TESTS, AND MEASUREMENTS
Tier 2 inspections, tests, and measurements generally require specialized equipment or expertise,
may be intrusive, or may require an outage to perform. A Tier 2 assessment is not considered routine.
Tier 2 inspections are intended to affect the Rotor Condition Index number established using Tier 1
tests as well as confirm or disprove the need for more extensive maintenance, rehabilitation, or
generator replacement.
Note that there are many tests that can provide information about the various aspects of rotor
condition. The choice of which tests to apply should be made based on known information obtained
via review of O & M history, physical inspection, other test results, and company standards as well as
the Tier 1 assessment. Many of the following Tier 2 tests are used to detect or confirm a similar
defect or state of deterioration. In the event that more than one Tier 2 tests are performed to assess
the same problem or concern, then the test with the largest adjustment shall be used to recalculate
the Rotor Condition Index.
4.2.1. TIER-2. ROTOR High-Potential Withstand
TIER 2. Table 26 – Rotor High-Potential Withstand Test Index Scoring

Passed withstand test
Failed withstand test.
4.2.2. TIER-2. ROTOR AC Pole Drop Test
This test is performed on salient pole rotors to detect shorted turns in the field winding or Turbo
generator with RR removal. The winding is energized at 120 V, 50 or 60 Hz and the voltage drop
across each pole is measured. Poles with appreciably lower voltage drops may have shorted turns.
The voltage drop across the immediately adjacent poles or pole turn (for turbo generator) may be low
as well due to the influence of the defective pole on the magnetic circuits of the adjacent poles.
TIER 2. Table 27 – Rotor AC Pole Drop Test Index Scoring

Poles reinsulated within last < 10 years
No indication of shorted turns
One pole (salient) / one slot (turbo) with one shorted turn
Two or more poles (salient) / two or more slots (turbo) with one
shorted turn
One or more poles (salient) / ones or more slots (turbo) with multiple
shorted turns

4.2.3. TIER-2. ROTOR Field Winding AC Impedance

Due to the appreciable centrifugal forces that act on a rotor winding at rated speed, certain shorted
turns may only be apparent when the rotor is revolving at or near rated speed. An impedance test can
be performed while the machine is being shut down or brought up to speed to detect shorted turns
that are only present under centrifugal forces. To perform the test, a 120 V, 50 - 60 Hz power supply
is applied to the winding through the collector rings. The applied voltage and current are measured
and the impedance is calculated over a range of rotational speeds
TIER 2. Table 28 – Rotor AC Impedance Test Index Scoring

Difference between readings taken at rated speed and standstill is <
5%. No abrupt changes.
Difference between readings taken at rated speed and standstill is ≥
5% and < 10%. No abrupt changes.
5% and < 10%, with abrupt change ≥ 5%.
10% and abrupt change is ≥ 5%.
4.2.4. TIER-2. ROTOR Recurrent Surge Oscillation (RSO) valid for Turbo Generator
The “Generator Rotor Shorted Turn Analyzer” or (“RSO” Recurrent Surge Oscillation) produces a
succession of step-shaped low voltage pulses. The pulses are introduced simultaneously to the dc
rotor winding (“field winding”) from both ends. The resulting reflected signals can be viewed on a dual
channel oscilloscope screen as two separate waveforms, or after one of them is inverted, and both
summed as a single trace.
If no discontinuities are present in the winding (due to grounds or shorted-turns), both traces will be
nearly identical and if inverted and summed, a single trace will be displayed as a horizontal straight
line, with a minor blip at the origin and an almost imperceptible ripple. Any significant discontinuity
arising from a fault will be shown as an irregularity on the summed trace. By estimating the location
of the anomaly on the screen, an inference can be made as to the approximate location of the fault.
For instance, large irregularities near the origin of the trace are attributed to faults close to either end
of the winding.
TIER 2. Table 29 – RSO (Recurrent Surge Oscillation) Test Index Scoring

Stable readings in one trace graph taken at rated speed and or
standstill no changes and no short turn indication
Slightly unstable readings still in one trace graph taken at rated speed
and or standstill no changes and no short turn indication
Slightly different readings trace graph taken at rated speed and or

standstill and little short turn indication

Significant different readings trace graph taken at rated speed and or
standstill and significant short turn indication
4.2.5. Rotor Condition Summary TIER-2
TABLE 30. TIER 2 ROTOR CONDITION SUMMARY

No TIER 2 TEST ROTOR ROTOR CONDITION INDEX
Table 25 TIER 2.– Rotor High-Potential Withstand Test Index
Scoring
Table 26 TIER 2.– Rotor AC Pole Drop Test Index Scoring
Table 27 TIER 2.– Rotor AC Impedance Test Index Scoring
Table 28 TIER 2.– RSO (Recurrent Surge Oscillation) Test Index
Scoring
Tier 2 Adjustments to Stator Condition Index
(Sum of individual Adjustments)
Calculation NET Rotor Condition Index
To calculate the Net Rotor Condition Index (Value should be between 0 and 10), subtract the Tier 2
Adjustments from the Tier 1 Rotor Condition Index:
Net Rotor Condition Index = Rotor Condition Index Tier 1 – Rotor Condition Index Tier 2
Tier 1 Rotor Condition Index __________

Tier 2 Rotor Condition Index __________
____________________________________
Net Rotor Condition Index =

TABLE 31. ROTOR DATA QUALITY SCORING TIER 2

Stator Data Quality
Results
Indicator Score
10
7
and < 36 months past the normal testing frequency, or some of the results are not 4
months past the normal frequency, or no results are available or many are of 0
Tier 1 Rotor Data Quality Indicator

Determine the Tier 2 Generator Rotor Condition Index
To determine the Net Generator Rotor Condition Index (Value should be between 0 and 10), choose
the lower of the Net Rotor Condition Index.
Record the Data Quality Indicator associated with the chosen Condition Index:
Net Rotor Generator Condition Index _____________
Data Rotor Quality Indicator ______________
ROTOR GENERATOR CONDITION

ROTOR SUGGESTION OF ACTION
INDEX
Continue O & M without restriction. Repeat condition
≥ 7.0 and ≤ 10 (Good)
assessment as needed.
Continue operation but re-evaluate O & M practices Consider
≥ 3.0 and < 7 (Fair)
using appropriate Tier 2 tests. Repeat condition assessment
process as needed.
Immediate evaluation including additional Tier 2 testing.
≥ 0 and < 3.0 (Poor)
Consultation with experts. Adjust O & M as prudent. Begin
replacement/rehabilitation process

5. Advance Analysis
5.1. Arhaenus Life Curve
The machine insulation is subjected to constant

thermal stress that causes aging as given by the
Arrhenius chemical degradation rate equation and
charts for different insulation class. Besides this,
there are cyclic thermal stresses caused by
frequent starts/stop of the machine. This causes
reduction in tensile strength of the insulation,
which can be expressed in terms of residual
breakdown voltage (RBDV). The basic Arrhenius
curves are modified to account for the operational
hours and starts/stops as shown.
5.2. BDV (Breakdown Voltage)

It is assumed that the BDV for new machines
is 100%. There is initial reduction in BDV
(shown by BDV1) due to stresses caused by
heating of windings and insulation,
corresponding to the operating hours. The
stresses are high during starting and stopping
conditions, which further reduce the BDV
(shown by BDV2). The value of 60% for BDV
is taken as the critical value, below which the
machine is at high risk of insulation failure.
Some independent company use constanta m
= 20, and manufacture based on CIGRE m = 30 (Alstom GESE 066261C. Index B)
The coefficient 30 used to transform a number start stop in Equivalent hours is the one universally
adopted the world constructions and recognized by the CIGRE
5.3. Calculation of EOH (Equivalent Operating Hours)
EOH = H1 + 30 Nd. H1 = No of operating hrs at nominal speed. Nd = No of Starting

(Alstom GESE 066261C. Index B)

Considering surge absorber, the generator is required withstanding voltage more than 2E+1kV in 1
minute, with E= Voltage Rating at rms. This breakdown is equivalent to 40% of mean value of initial
withstanding voltage. The voltage surge (2E+1kV) possibly brake into the generator insulation. Thus,
generator is required dielectric strength more than (2E+1 kV ac)
The above analysis based on operational data can offer life cycle estimation at 65% confidence level,
or at least the BDV not fall until 40%, The next step in life cycle is to evaluate the present machine
condition by diagnostic test.
The tests gives in depth information regarding machine abnormalities like contamination, lack of
contact of coil with core, looseness of coil/wedges, presence of voids within insulation, presence of
partial discharges and its location, core lamination shorting and so much more. These parameters will
further degrade the insulation properties and reduce the RBDV or tensile strength. The curves are
suitably corrected to yield the life cycle of the machine.
The change in the winding temperature from a cold to hot condition and from a hot to cold condition
constitutes a thermal cycle. Thermosetting insulation systems generally are stable dimensionally with
increase/decrease in temperature. However, the copper of the bars tends to expand on application of
heat. The restraining force is generally offered by the end-winding bracing supports that are used to
limit winding movement due to electro-magnetically-generated forces. These constraints result in a
mechanical strain at certain bracing support locations. Also, the conductor bends and twists due to a
change in the direction of expansion of the coil, resulting in additional development of stresses.
5.4. BDV Calculation
Example:
Total number of operating hours : 32,782 hours
Total no. of starts/stops : 3,971
Present equivalent hours : 151,912.0 Hours (Op. Hours + 30 * Starts/Stops)
The residual BDV corresponding to above data: app. 73.5 % ,
See Curve as shown below (modification of Arhaenus Curve)
If we now consider the estimated discharging void content, the amount of accumulated charge
(particularly due to ion migration phenomena), and the extent of leakages, a reduction in the BDV is
evaluated for every machine based on the measured quantities and observed conditions.

Page 30
1 of 41
ITP – 07-0515-R1

Doc.Code
510,000
Page(s)
495,000
380,000 480,000
370,000 465,000
360,000 450,000
350,000
340,000 435,000
330,000 420,000
320,000 405,000
Min. Limit BDV

310,000 390,000
EQUIVALENT OPERATING HOURS

300,000
1
375,000
290,000
May 30, 2018
280,000 360,000
270,000 345,000
Revision
260,000 330,000
ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR

250,000 315,000
BDV vs OPERATING HOURS
Date
240,000
300,000
OPERATING HOURS
230,000
220,000 285,000
210,000
BDV VS EOH
270,000
200,000 255,000
190,000
180,000 240,000
Specialist Engineer
Life Cycle
170,000 225,000
160,000 210,000
150,000 195,000
140,000
130,000 180,000
165,000
Siswanto
120,000
110,000 150,000
Issued
100,000 135,000
Safety Limit BDV

90,000
80,000 120,000
Present EOH
70,000 105,000
60,000 90,000
B…
50,000 75,000
40,000
30,000 60,000
20,000 45,000
10,000 30,000
- 15,000
-
9.50
9.00
8.50
8.00
7.50
7.00
6.50
6.00
5.50
5.00
4.50
4.00
3.50
3.00
2.50
2.00
1.50
1.00
0.50
10.50
10.00
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
BREAK DOWN VOLTAGE SCALE BREAKDOWN VOLTAGE IN %
Dielectric Strength (BDV) vs Machine Hours

14,000
12,000 80%
40% Lowest
10,000
Start-Stop
BDV1
8,000 50%
BDV2
6,000
BDV3
4,000 60%
BDV4
2,000 70% BDV5
0
0 50,000 100,000 150,000 200,000 250,000 300,000
Operating hour (hours)

6. TEST REFRENCES
 IEEE 62.2 - Guide for Diagnostic Field Testing of Electric Power Apparatus Electrical
Machinery.
 IEEE 43- Recommended Practice for Testing Insulation Resistance of Rotating Machinery.
 IEEE 56 - Guide for Insulation Maintenance of Large Alternating-Current Rotating Machinery
(10 000 kVA and Larger).
 IEEE 1434 / D.1.1 - Guide for the Measurement of Partial Discharges in AC Electric
Machinery.
 IEEE 95 - Recommended Practice for Insulation Testing of AC Electric Machinery (2300 V
and Above) With High Direct Voltage.
 IEEE 115 - Guide: Test Procedures for Synchronous Machines.
 IEEE 286 - Recommended Practice for Measurement of Power Factor Tip-Up of Electric
Machinery Stator Coil Insulation
7. SCOPE OF WORKS
7.1. INSPECTION AND TEST
7.1.1. STATOR
- Visual inspection
- Endoscopic inspection to trace the PD tracking in the stator slot region
- Insulation resistance and polarization index Test
- DC winding resistance Test
- Dissipation Factor Tan delta Test
- Capacitance Mapping Test
- Off line PD probe Test
- ELCID Test
- Stator Wedge Analysis (SWA) Test
- PDCA (Polarization Depolarization Current Analysis) Test
- FDS (Frequency Domain Spectroscosphy) Test
- Leakage current test by DC Hipot Test
- Coupling Resistance test
- Core tightening Inspection
7.1.2. ROTOR
- Visual inspection
- Endoscopic inspection to inspect the rotor winding part at underneath retaining rings

- PDCA (Polarization Depolarization Current Analysis) Test

- RSO (Recurrent Surge Oscillosgraph) test
- AC Impedance
- Pole Balance test
- NDT for mechanical parts such as retaining rings, bearings, journal.
7.1.3. EXCITER
- Visual inspection
7.2. Analysis Modeling

- Scoring Modeling
- BDV calculation

8. SITE DOCUMENTATION FOR REFERENCES
PDCA-FDS Combined test on GE 20MW / 13.8kV/ 3600 RPM and GE 33MW / 13.8kV / 3600 RPM

PDC graph for all phases
FDS graph for all phases

Tan Delta on GE Generator 33 MW / 13.8kV
Stator wedge analysis using Rebound Impact Energy

PD Probe test

PDC test on the rotor turbo generator
RSO test on the rotor

Rewinding personnel experiences (rotor and stator)



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PT.

VOLTA TERAWINDO BHUWANA

Generator analyzing by “GENERATOR SCORING INDEX”

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 1

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 2

2.3. WEIGHTING FACTORS

3. TESTING TIER 1. STATOR

3.1. Stator Condition Indicator

3.1.1. Stator Condition Indicator 1 – Operation & Maintenance History

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 3

Unbalanced phase operation

TIER 1. TABLE 1 – STATOR WINDING OPERATION & MAINTENANCE HISTORY SCORING

3.1.2. Stator Condition Indicator 2 – Physical Inspection

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 4

TIER 1. Table 2 – Stator Winding Physical Inspection Scoring

3.1.3. Insulation Resistance and Polarization Index

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 5

3.1.4. Winding DC Resistance

TIER 1. Table 4 – Stator Winding DC Resistance Index Scoring

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 6

3.1.5. Stator Condition Indicator 4 – Winding Age

TIER 1. Table 5 – Stator Winding Age Index Scoring

3.1.6. TIER 1 – STATOR CONDITION INDEX CALCULATIONS

Calculation the Tier 1 Stator Condition Index

TIER 1. Generator Stator Condition Summary

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 7

3.1.7 TIER 1 – STATOR DATA QUALITY INDICATOR

TABLE 6. STATOR DATA QUALITY SCORING

Tier 1 Stator Data Quality Indicator

SUMMARY TIER 1 . STATOR

Generator Condition Index Stator _______________

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 8

3.2. TEST TIER 1 : ROTOR

3.2.1. Rotor Condition Indicator 1 – Operation & Maintenance History

Maintenance needs increasing with time or problems are re-occurring.

TIER 1. Table 7 – Rotor Operation & Maintenance History Index Scoring

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 9

3.2.2. Rotor Condition Indicator 2 – Physical Inspection

Rotor Turbo Generator

Rotor Hydroelectric Generator

TIER 1. Table 8 – Rotor Physical Inspection Index Scoring

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 10

3.2.3. Rotor Condition Indicator 3 – Insulation Resistance and Polarization Index

3.2.4. Rotor Condition Indicator 4. Rotor Winding DC Resistance

TIER 1. Table 10 – Rotor Winding DC Resistance Index Scoring

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 11

3.2.5. Rotor Condition Indicator 5 – Winding Age

TIER 1. Table 11 – Rotor Winding Age Index Scoring

3.2.6. TIER 1 – ROTOR CONDITION INDEX CALCULATIONS

Calculation the Tier 1 Rotor Condition Index

TIER 1. Generator Rotor Condition Summary

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 12

3.2.6.1. TIER 1 – ROTOR DATA QUALITY INDICATOR

TABLE 12. TIER-1 ROTOR DATA QUALITY SCORING

Tier 1 Rotor Data Quality Indicator

SUMMARY TIER 1 . ROTOR

Generator Condition Index Rotor _______________

ITP 07-0515: LIFE CYCLE ANALYSIS OF GENERATOR AND MOTOR Page 13

4. TIER 2 – STATOR INSPECTIONS, TESTS, AND MEASUREMENTS