INVESTIGATION INTO THE POSSffill.

ITY OF USING PARTIAL

DISCHARGE MEASURING EQUIPMENT TO DIAGNOSE FAULTS ON
3,3 KV MACIDNES

by

Dennis Raymond Willemse

Thesis submitted in fulfilment of the requirements for the degree

Magister: Technologiae: Engineering: Electrical

In the

Faculty of Engineering, Information

and Communication Technology

at the

Central University ofTechnology

Supervisor: Mr. P. Hertzog, M.Tech. (Eng.)

Co-Supervisor: Mr. M. Naude, M.Sc. (Eng.)

BLOEMFONTEIN
April2004

© Central University of Technology, Free State

DECLARATION OF INDEPENDENT WORK

I, DENNIS RAYMOND WILLEMSE, hereby declare that this research project

submitted for the degree MAGISTER TECHNOLOGIAE: ENGINEERING:
ELECTRICAL, is my own independent work that has not been submitted before to any
institution by anyone else or me as part of a qualification.

/0 J1p,eit_,
....... ..... Day of.. .... . ... .... ............ 2004

© Central University of Technology, Free State

ACKNOWLEDGEMENT

I would like to thank the following persons and instances for their help and contribution
towards the completion of this project:

My colleagues at lscor Flat Steel Products for all their technical inputs.

The relevant manufacturers and repairers of electrical machines in Gauteng, for valuable
information received from them.

A special thanks to Westward Electric and Iris Power Engineering for the loan of the
Partial Discharge equipment.

My wife and family, without whose support, this project would not have been possible.

ii

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SYNOPSIS

It is a widely recognised fact that the presence of Partial Discharge activity in machines
with an operating voltage exceeding 6,6 kV, enables periodic on-line monitoring of the
condition of these machines. Analysis of the discharge activity, can assist maintenance
personnel in determining if a winding has become loose, contaminated or if the
insulation condition is deteriorating.

However, very little information exists regarding PD activity in machines with an

operating voltage of 3,3 kV. Although some studies have been conducted, that dealt
with measurement techniques and continuous on-line monitoring of 3,3kV machines,
very few investigated the discharge levels or failure mechanisms associated with
different types of machines.

Due to the large amount of critical 3,3 kV machines at Iscor Flat Steel Products, it was
deemed necessary to investigate the possibility of applying the same techniques to these
machines, in order to determine the condition of the windings.

Tests and analysis conducted with a PD Analyser and software manufactured by Iris
Power Engineering, indicated that it would be feasible to perform on-line testing of
certain 3,3 kV motors.

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UITTREKSEL

Dit is alom bekend dat die teenwoordigheid van Gedeeltelike Ontladings aktiwiteite in
elektriese masjiene met ' n bedryfspanning van meer as 6,6 kV dit moontlik maak om
die toestand van die masjiene aanlyn te bepaal. Wanneer 'n analise gedoen word van die
ontladings aktiwiteit, kan die instandhoudingspersoneel bepaal of ' n wikkeling los is, of
dit gekontamineer is en of die isolasietoestand besig is om te verswak.

Daar is egter baie mm inligting beskikbaar aangaande die Gedeeltelike Ontladings

aktiwiteit in masjiene met 'n bedryfspanning van 3,3 kV. Navorsing is al gedoen
rondom meet tegnieke en aaneenlopende aanlyn monitering van 3,3 kV masjiene, maar
min inligting is beskikbaar oor ontladingsvlakke en falingsmeganismes vir verskillende
tipes masj iene.

As gevolg van die groot hoeveelheid kritiese 3,3 kV masjiene by lscor Flat Steel
Products, is daar besluit om die moontlikheid te ondersoek of hierdie tegnieke ook op
die masjiene toegepas kan word, sodat die toestand van die wikkelings bepaal kan word.

Toetse en analises wat uitgevoer is met ' n Gedeeltelike Ontladings Analiseerder en

sagteware, soos verskaf deur Iris Power Engineering, het aangedui dat dit lewensvatbaar
is om aanlyn toetse op sekere 3,3 kV masjiene uit te voer.

IV

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ABBREVIATIONS AND SYMBOLS

ECMP Electrical Condition Monitoring Program

IEEE Institude of Electrical and Electronic Engineers
Iscor Iron and Steel Corporation
LPD Linear Pulse Density
NQN Normalized Quantity Number
PD Partial Discharge
PPA Pulse Phase Analysis
Qm Peak PD magnitude in Vm at I Opps
RF Radio Frequency
RTD Resistance Temperature Detector
SNR Signal-to-noise ratio
TGA-B Turbo Generator Analyser Model-B (Specific analyser used)
VPI Vacuum Pressure Impregnation

© Central University of Technology, Free State

 TABLE OF CONTENTS
Page
Declaration of independent work ................................................................................... i
Acknowledgement ........................................................................................................ ii
Synopsis ................................................................................................................ ...... iii
Uittreksel .................................................... ................................................................. iv
Abbreviations and symbols ............................................................................................ v
List of figures ............... .............................................................................................. xii
List oftables ................................ .............................................................................. x iii

CHAPTER I - INTRODUCTION ................................................................................ I

1.1 Introduction and background .................................................................... 1
1.2 The problem and its setting ...................... ................................................ 1
1.3 Objective of the research ................................................... ....................... 2
1.4 Hypothesis .................................... .. ......................................................... 2
1.5 Research methodology ............................................................................. 2
1.6 Assumptions ........ ... .................................................... ....... .. .................... 2

2 CHAPTER 2 -REVIEW OF THE RELATED LITERATURE ............... ..................... 3

2.1 Introduction ............................................................................................. 3
2.2 PD sources in rotating machine windings ................................................. 4
2 .3 Overview of Partial Discharge detection methods ..................................... 6
2.3.1 Electrical pulse sensing ............................................................................ 7
2.3.2 Radio frequency radiation sensing ............................................................ 8
2.3.3 Power-factor tip up ................................................................................... 8
2.3.4 Energy/integrated charge transfer ............................................................. 9
2.3.5 Ozone detection ....................................................................................... 9
2.3.6 Acoustic and ultrasonic detection ............................................................. 9
2.3.7 Black-outtest ........................................................................ ................. 10
2.4 Measurement techniques used ................................................................. 10

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 2.4.1 PD pulse shape ........ ................................................................ ............... I 0
2.4.2 PD sensors ................. ............ ..................................... ...................... ..... 11
2.4.3 Measurement system ........... ................................................................... 11

3 CHAPTER 3- PD CHARACTERISTICS OF FAILURE MECHANISMS ........... ..... 14

3.1 Relationship between PD pulse polarity and discharge location ............... 14
3.1.1 Cavities at the interface between the conductor and the ground-wall
insulation .................. .. .... ....... ... ............ ............ ..................... .............. .. 14
3 .1.2 Cavities near iron core ........... ................................................................. 15
3 .1.3 Voids in the bulk of the insulation ......................................................... 15
3 .1.4 Endwinding discharges .......................................................................... 15
3 .2 Load effect. ................................... ........... ............ .. .................... ............. 17
3.3 Temperature effect .................................................. .................... .. .......... 18
3.3. 1 Negative temperature effect... ..................................................... ............ 18
3.3.2 Positive temperature effect ............................................................... ...... 18
3.4 Specific failure mechanisms ........... ................ ......... .. .............................. 18
3 .4.1 Thermal deterioration .......................... ............. ........... ...................... ..... 18
3.4.2 Phase-to-phase PD activity .................................................... ................. 19
3.4.3 Loose Coils ............................................................................................ 21
3.4.4 Electrical slot discharge .......................................................................... 21
3.4.5 Inadequate spacing between coils ...................... ............ ......................... 22
3.4.6 Improper impregnation .. ........... .. ......................................................... ... 22
3.4.7 Semicon/grading coating interface deterioration ..................................... 22

4 CHAPTER 4 - INTERPRETING TGA RESULTS ..................................................... 23

4.1 PD view software ........ ...................................................... ...................... 23
4.1.1 Pulse height analysis ...... .. ............ ................................................ .......... 23
4.1.2 Pulse phase analysis ............................................................................. .. 24
4.2 Advance view software .................................................................. ...... ... 25
4.2.1 Polar plot ............................. ..................... ............. ................................ 25
4.2.2 Trend plots .. ........... .............. ........... .............. ............ ............................. 26
4.2.3 Linear pulse density plot ...... ............ .. ............. ....................................... 27

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5 CHAPTER 5 -COIL CONSTRUCTION AND INSULATING SYSTEMS ............... 29
5.1 Coil construction ..................................................................................... 29
5.1.1 Form wound windings ............................................................................ 29
5.1.2 Random wound windings ........................................ ............................... 30
5.2 Insulating Systems ............. ..................................................................... 31
5.2.1 Dip ......................................................................................................... 31
5.2.2 Vacuum pressure impregnation ........................................ ...................... 31
5.2.3 Resin-rich (B-stage) system .................................................................... 32

6 CHAPTER 6- METHODS AND TECHNIQUES .. .................................................... 33

6.1 Devising a method of testing 3,3 kV machines for research purposes ...... 33
6.1.1 Constructing a portable test kit to perform temporary PD testing ............ 33
6.2 Testing techniques .................................................................. ................. 34
6.2.1 Routine PD testing at the Test Floor .................. .................................. ... 34
6.2.1.1 Testing procedures ................................................................................. 34
6.2.2 Special PD testing at the Test Floor ........................................................ 35
6.2.3 Tests conducted in the plant environment.. .............................. ............... 36
6.3 PD analysis method .................................................... ............................. 36
6.3.1 PD analysis principles for electrical machines with design operating
voltages of 6,6 kV and above .... ............................................................. 36
6.3 .1.1 Classic PD flowchart [3, p. 59] ................ .................................. ............. 38
6.3.1.2 Non-classic PD flowchart [3, p. 60] ........................................................ 39
6.3.2 Analysis Matrix .. .................................................................................... 40
6.3.2.1 Explanation of matrix abbreviations ...................... ................................. 41
6.3.3 Discharge Magnitudes ............................... ............ ......... ........................ 41

7 CHAPTER 7- PD TESTING AT THE TEST FLOOR .. ............................................. 43

7.1 Introduction ............................................................................................ 43
7.2 PD test results and analysis data .............................................................. 43
7.2.1 Winding type: Form coi l ........................................................................ 43
7.2.1.1 Impregnation method - unknown insulation system ............................... 43
7.2.1.1.1 Motor# 150XX3 .................. ........................... ....................................... 43

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 7.2.1.2 Impregnation method: Dip (lsonel) .... ..................................................... 46
7.2.1.2.1 Motor # 400BA2 .......................................................... .......................... 46
7.2.1.3 Impregnation method: Resin rich insulation system ...... ...................... .... 49
7.2.1.3.1 Motor # 160BF I ............................................... ...................................... 49
7.2.1.3.2 Motor # I60BF3 ..................................................................................... 50
7.2.1.3.3 Motor # 160BF I1 ...................................................... ............................. 51
7.2.1.3.4 Motor # 200DP2 ........... ....................................... ...................... .......... .. 53
7.2.1.3.5 Conclusion summary for resin rich motors tested at the Test Floor ......... 55
7.2.1.4 Impregnation method: Vpi insulation system .......................................... 56
7.2.1.4.1 Motor # 185CD I .................................................................................... 56
7.2.1.4.2 Motor# 220AA5 ........................... ......................... .. .............................. 58
7.2.1.4.3 Motor # 250BB4 ............................. .......... ............................................. 61
7.2.1.4.4 Motor # 300AA3 .................................................................................... 63
7.2.1.4.5 Motor# 305AA2 .................................................................................... 66
7.2.1.4.6 Motor# 380ABJ ..................................................................... ............... 69
7.2.1.4. 7 Motor# 380XX1 .................... ........................... ..................................... 73
7.2.1.4.8 Motor # 400KW GEC ....................................... ..................................... 76
7.2.1.4.9 Motor# 585AA2 ........ ............................................................................ 78
7.2. 1.4.10 Conclusion summary for vpi motors tested at the Test Floor ................... 81
7.2.2 Winding type: Random wound ........................... .................................... 82
7.2.2. 1 Motor# 160BB3 ............. .. ............................................................ .. ....... 82
7.2.2.2 Motor# 175BD3 ........... .................. ..................................... .................. 85
7.2.2.3 Motor # 240AB3 .................................................................................... 87
7.2.2.4 Motor# 250BC3 .... ................................................................................ 90
7.2.2.5 Motor # 400CE 1 ...... ............. ............... ............ ...................... ................ 93
7.2.2.6 Conclusion summary for random wound motors tested at the Test Floor 95
7.2.3 Winding type: Unknown ........................................................................ 96
7.2.3.1 Motor # 400CH 1 .................................................................................... 96

8 CHAPTER 8 - PD TESTING OF SPECIAL MACHINES ...... ................................... 99

8.I Introduction .............................................. .......................................... .... 99
8.2 Testing of motor # 250BB3 .................................... ................................. 99

ix THIS BOOK IS THE

PROPERTY OF THE

2005 -03- 8-
CENTRAL UNIVERSITY OF
TECHNOLOGY, FREE STATE

© Central University of Technology, Free State

 8.3 Testing of motor# 250CG2 ................................................................... 102

9 CHAPTER 9 - PD TESTING IN A PLANT ENVIRONMENT ............................. ... I 07

9.1 Introduction ............. ............................................................................. 107
9.2 Plant testing ........................... ............................................................... 108
9.2.1 Motors tested with very low PD values ................................................ I 08
9.2.1.1 Motor # 150CL2 .................................................................................. 108
9.2.1.2 Motor# I60BF1 ................................................................................... I08
9.2.1.3 Motor # I60BF3 .................... ............................................................... 109
9.2.1.4 Motor# 160BF IO.... ............................ ................................................. 110
9.2.1.5 Motor# 250BC 1 .................................................................................. 111
9.2.1.6 Motor# 250BC2 ...................... ............................................................ 112
9.2.1.7 Motor # 250BC3 .................................................................................. 1 I 2
9.2.1.8 Motor# 250BC4 ........................................................................ .......... 113
9.2.1.9 Motor # 435AA3 .................................................................................. 114
9.2.1.10 Conclusion summary ..................................................... ....................... 114
9.2.2 Motors tested with significant PD values .. ............................................ 115
9.2.2.1 Motor# 150CL3 .................................................................................. 115
9.2.2.2 Motor# 160BF2 ............ ....................................................................... 117
9.2.2.3 Motor# 180CC4 .................................... .. ............................................ 118
9.2.2.4 Motor# 305AA2 ........... .. ........................................................... .......... 120
9.2.2.5 Motor# 380AB I .................................................................................. 122
9.2.2.6 Motor# 435AA5 ...................................... .................................. .......... 123
9.2.2.7 Motor# 500BJ 1 .. ......... .. ................ ...................................................... 125
9.2.2.8 Motor# 500BJ2 ................................................................................... 127
9.2.2.9 Motor # 500BJ3 ........................... ............. ....................... .................... 128
9.2.2.1 0 Motor# 950AA3 .................................................................................. 130
9.2.2.1 1 Conclusion summary for motors tested in the plant .............................. 132
9.3 Winding data ............................................... ................................... ....... l 32

IO CHAPTER 10 - CONCLUSIONS AND RECOMMENDATIONS .......................... 134

I O.I Findings ................................................................................................ 134

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10.1.1 The relationship between PD magnitudes and type testing .................... 134
10.1.1.1 Routine PD testing performed at the Test Floor .................................... 134
10.1.1.2 PD testing in a plant environment......................................................... 134
10.1.2 Relationship between PD magnitudes and coil construction types ........ 134
10.1.3 Correlation between discharge patterns for 3,3 kV machines and
established failure mechanisms for higher voltage machines ................ 137
10.1.3.1 Phase-to-phase related discharges ......................................................... 137
10.1.3.2 End-winding contamination ................................................................. 138
10.1.3.3 Inadequate spacing between coils ......................................................... 138
10.1.3.4 Electrical slot · discharge and semicon/grading coating interface
deterioration ......................................................................................... 139
10.1.3.5 Improper impregnation......................................................................... 139
10.1.3.6 Loose coils ........................................................................................... 140
10.1.3.7 Thermal deterioration ........................................................................... I 40
10.2 Conclusions .......................................................................................... 140
10.3 Final statement and recommendation ..................................................... l41
List of references ....................................................................................................... 142
Appendices (Graphical appendixes are stored on a CD attached to the back cover) ... 145

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LIST OF FIGURES
Page

Figure 2.1: Dielectric circuit of insulation .......................... ........... ............................. 4

Figure 2.2: Insulation composition of a form coil.. .................................................... . 6
Figure 2.3: Directional Time-of-Arrival Noise Cancellation method ........................ 12
Figure 3.1: Pulse polarity based on cavity location ................................................... 14
Figure 3.2: Three- phase vector diagram of a rotating machine ................................ 20
Figure 3.3: Multiple vector diagram ......................................................................... 21
Figure 4.1: Pulse height analysis of PD ...................................................... .............. 23
Figure 4.2: Pulse phase analysis ofPD ............................................. ........................ 25
Figure 4.3: Polar plot ofPD ..................................................................................... 26
Figure 4.4: Trend plot of PD ............................................................. .. .................... . 26
Figure 4.5: Linear pulse density plot.. ...................................................................... 27
Figure 5.1: Construction of a Form coil ................................................................... 30
Figure 5.2: Construction of a Random wound coil ................................................... 31
Figure 6.1: Original portable test kit.. ....................................................................... 34
Figure 6.2: Improved portable test kit ...................................................................... 34
Figure 7.1: End-winding of motor # 380AB I ........................................................... 70
Figure 8.1: Skew coils of motor # 250883 .. .............................................................. 101
Figure 8.2: Centre filler for motor# 250BB3 ......................................................... 102
Figure 8.3: Enlarged view of centre filler .................................................. ............. I 02
Figure 8.4: Relationship between PD and temperature ........................................... 104
Figure 8.5: End-winding of motor# 250CG2 ......................................................... 105
Figure 8.6: Enlargements of PD activity on line-end coil for motor# 250CG2 ....... 106
Figure 8.7: 30X enlargement ofPD activity on line-end coil of motor# 250CG2 ... 106
Figure 9.1: Motor# 150CL3 .................................................................................. 107

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LIST OFTABLES
Page
Table 6.1: Testing cycles to determine possible failure mechanisms ........................35
Table 6.2: Analysis matrix ...................................................................................... 40
Table 6.3: Discharge magnitudes at different loads and temperatures ......................41
Table 7.1: Nameplate data for motor# 150XX3 ........................................... ....... ... .43
Table 7.2: Discharge magnitudes for motor# 150XX3 ...................... ..................... .43
Table 7.3: Analysis matrix for motor # 150XX3 ............. ......... ............ .................. .44
Table 7.4: Winding configuration ...................................... .....................................45
Table 7.5: Nameplate data for motor # 400BA2 ............................................. .........46
Table 7.6: Discharge magnitudes for motor # 400BA2 .... ................................. ...... .46
Table 7.7: Analysis matrix for motor# 400BA2 ............................................... ...... .46
Table 7.8: Winding configuration for motor # 400BA2 .......................................... .4 7
Table 7.9: Nameplate data for motor # 160BF 1...................................................... .49
Table 7.10: Discharge magnitudes for motor# 160BF1 ...... ..................................... .49
Table 7.11: Analysis matrix for motor# 160BF1 ......................................................49
Table 7.12: Winding configuration for motor# 160BF1 ...... ....................... ........... ....50
Table 7.13: Nameplate data for motor# 160BF3 ....................................................... 50
Table 7.14: Discharge magnitudes for motor# 160BF3 ............................................50
Table 7.15: Analysis matrix for motor# 160BF3 ...................................................... 51
Table 7. 16: Winding configuration for motor# 160BF3 ......................................... ... 51
Table 7. 17: Nameplate data for motor# 160BF11 ....... ............................................. .51
Table 7.18: Discharge magnitudes for motor# 160BF 11.. ......................................... 52
Table 7. 19: Analysis matrix for motor# 160BF11 .................................................... 52
Table 7.20: Winding configuration for motor# 160BF11 ........... ....................... ........ 52
Table 7.21: Nameplate data for motor# 200DP2 ........ ... ........... ................................ 53
Table 7.22: Discharge magnitudes for motor# 200DP2 .... ........................................53
Table 7.23: Analysis matrix for motor # 200DP2 ...................................................... 54
Table 7.24: Winding configuration for motor# 200DP2 ........................................... 55
Table 7.25: Nameplate data for motor# 185CD1 ............. ........... ............ .................. 56
Table 7.26: Discharge magnitudes for motor# 185CD1 ..... ........ .... ........................... 56
Table 7.27: Analysis matrix for motor# 185CD1.. .. .................................................. 57

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Table 7.28: Winding configuration for motor # 185CDI ........................................... 58
Table 7.29: Nameplate data for motor# 220AA5 ...................................................... 58
Table 7.30: Discharge magnitudes for motor# 220AA5 ........... ................................. 59
Table 7.31: Analysis matrix for motor# 220AA5 .....................................................59
Table 7.32: Winding configuration for motor # 220AA5 ........................................... 60
Table 7.33: Nameplate data for motor# 250 BB4 ........ ... ....... ................................... 61
Table 7.34: Discharge magnitudes for motor# 250BB4 ............................................ 61
Table 7.35: Analysis matrix for motor # 250BB4 ........... .. ......................................... 62
Table 7.36: Winding configuration for motor# 250BB4 ........ ..................... ........... ... 63
Table 7.37: Nameplate data for motor # 300AA3 ...................................................... 63
Table 7.38: Discharge magnitudes for motor# 300AA3 .... ................................. ....... 64
Table 7.39: Analysis matrix for motor# 300AA3 ........................ ............................. 64
Table 7.40: Winding configuration for motor# 300AA3 ........................................... 65
Table 7.41: Nameplate data for motor# 305AA2 ...................................................... 66
Table 7.42: Discharge magnitudes for motor# 305AA2 ............................................ 66
Table 7.43: Analysis matrix for motor# 305AA2 ..................................................... 67
Table 7.44: Winding configuration for motor# 305AA2 ...... ...................... .......... ..... 68
Table 7.45: Nameplate data for motor # 380AB I ...................................................... 71
Table 7.46: Discharge magnitudes for motor # 380A B 1 ............................................ 71
Table 7.47: Analysis matrix for motor# 380AB 1...................................................... 72
Table 7.48: Winding configuration for motor# 380AB1 ........ ............................... .... 73
Table 7.49: Nameplate data for motor# 380XXI .................... .................................. 73
Table 7.50: Discharge magnitudes for motor# 380XX1 ............................................ 74
Table 7.51: Analysis matrix for motor # 380XXI ..................................................... 74
Table 7.52: Winding configuration for motor# 380XX1 .................................. ......... 75
Table 7.53: Nameplate data for motor# 400KW GEC ...................................... ........ 76
Table 7.54: Discharge magnitudes for motor # 400KW GEC ...... .............................. 76
Table 7.55: Analysis matrix for motor# 400KW GEC ...................................... ........ 77
Table 7.56: Winding configuration for motor# 400KW GEC ................................... 78
Table 7.57: Nameplate data for motor# 585AA2 ...................................................... 78
Table 7.58: Discharge magnitudes for motor# 585AA2 ............................................ 79
Table 7.59: Analysis matrix for motor# 585AA2 ..................................................... 79

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Table 7.60: Winding configuration for motor# 585AA2 .................. ......................... 80
Table 7.61 : Nameplate data for motor# 160883 ........................................ ........... ... 82
Table 7.62: Discharge magnitudes for motor# 160883 ............................. .. ............ .82
Table 7.63: Analysis matrix for motor # 160883 ...................................................... 83
Table 7.64: Winding configuration for motor# 160883 ........ ................................... 84
Table 7.65: Nameplate data for motor# l758D3 .................... .................................. 85
Table 7.66: Discharge magnitudes for motor# 1758D3 ............. ....................... ........ 85
Table 7.67: Analysis matrix for motor# 1758D3 ........ .............................................. 86
Table 7.68: Winding configuration for motor# l758D3 ........................................ ... 87
Table 7.69: Nameplate data for motor # 240A83 ...................................................... 87
Table 7.70: Discharge magnitudes for motor# 240A83 ............................................ 88
Table 7.71: Analysis matrix for motor# 240A83 .................................... .................. 88
Table 7. 72: Winding configuration for motor# 240A83 ..................................... ...... 89
Table 7.73: Nameplate data for motor # 2508C3 ...................................................... 90
Table 7.74: Discharge magnitudes for motor# 2508C3 ............................................ 90
Table 7.75: Analysis matrix for motor# 2508C3 .... ............ ........... ...........................91
Table 7.76: Winding configuration for motor# 2508C3 ...... ..................................... 92
Table 7.77: Nameplate data for motor # 400CE1 ......................................................93
Table 7.78: Discharge magnitudes for motor# 400CEI ............................................ 93
Table 7.79: Analysis matrix for motor# 400CE1 .................. ..................... ............... 94
Table 7.80: Winding configuration for motor# 400CE1 ........................................... 95
Table 7.81: Nameplate data for motor# 400CH1 .................... .................................. 96
Table 7.82: Discharge magnitudes for motor# 400CH1 ............................... ............. 96
Table 7.83: Analysis matrix for motor# 400CH1 ...................................................... 97
Table 7.84: Winding configuration for motor# 400CH1 ........................................... 98
Table 8.1: Load cycle for motor# 250BB3 .................. ......... .. ...................... ........ ..99
Table 8.2: Analysis matrix for motor # 250883 ............. ..................... ............. ..... 100
Table 8.3: Relationship between PD and temperature of motor # 250CG2 ............ 103
Table 9.1: Nameplate data for motor # 150CL2 .................................................... ! 08
Table 9.2: Discharge magnitudes for motor# 150CL2 ...................................... .... 108
Table 9.3: Nameplate data for motor# 1608F1 ............................................... .. .... 108
Table 9.4: Discharge magnitudes for motor# 160BF1 ...... .................................... 109

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Table 9.5: Nameplate data for motor# 160BF3 .................... ................................. 109
Table 9.6: Discharge magnitudes for motor # 160BF3 .......................................... 109
Table 9.7: Nameplate data for motor# 160BF8 ..................................................... 11 0
Table 9.8: Discharge magnitudes for motor# 160BF8 .......................................... 11 0
Table 9.9: Nameplate data for motor# 160BF10 ................................................... 110
Table 9.10: Discharge magnitudes for motor# 160BF10 ......................................... 111
Table 9.11: Nameplate data for motor# 250BC1 .................................................... 111
Table 9.12: Discharge magnitudes for motor# 250BC1 .......................................... 111
Table 9.13: Nameplate data for motor# 250BC2 .................................................... 112
Table 9.14: Discharge magnitudes for motor# 250BC2 .......................................... 112
Table 9.15: Nameplate data for motor# 250BC3 .................................................... 112
Table 9.16: Discharge magnitudes for motor # 250BC3 .......................................... 113
Table 9.17: Nameplate data for motor# 250BC4 ............................................... ..... 113
Table 9.18: Discharge magnitudes for motor # 250BC4 .......................................... 113
Table 9.19: Nameplate data for motor# 435AA3 .................................................... 114
Table 9.20: Discharge magnitudes for motor# 435AA3 .......................................... 114
Table 9.21: Nameplate data for motor# 150CL3 ........................ ............................ ! 15
Table 9.22: Discharge magnitudes for motor# 150CL3 .......................................... 115
Table 9.23: Analysis matrix for motor H 150CL3 .................................................... 115
Table 9.24: Nameplate data for motor# 160BF2 ..................................................... 117
Table 9.25: Discharge magnitudes for motor# 160BF2 ...... .................................... 117
Table 9.26: Analysis matrix for motor# 160BF2 .................. .................................. 117
Table 9.27: Nameplate data for motor# 180CC4 .................................................... 118
Table 9.28: Discharge magnitudes for motor# 180CC4 .......................................... 119
Table 9.29: Analysis matrix for motor# 180CC4 .................. .................................. 119
Table 9.30: Nameplate data for motor# 305AA2 .................................................... 120
Table 9.31: Discharge magnitudes for motor# 305AA2 .......................................... 120
Table 9.32: Analysis matrix for motor# 305AA2 ................................................... 121
Table 9.33: Nameplate data for motor# 380AB1 .................................................... 122
Table 9.34: Discharge magnitudes for motor# 380AB 1 .......................................... 122
Table 9.35: Analysis matrix for motor# 380AB1 .................................................... 122
Table 9.36: Nameplate data for motor# 435AA5 .................................................... 123

XVI

© Central University of Technology, Free State

Table 9.37: Discharge magnitudes for motor# 435AA5 .......................................... 124
Table 9.38: Analysis matrix for motor# 435AA5 ................................................... 124
Table 9.39: Nameplate data for motor# 500BJ1 ..................................................... 125
Table 9.40: Discharge magnitudes for motor# 500BJ1 ........................................... 125
Table 9.41: Analysis matrix for motor# 500BJ1 ..................................................... 126
Table 9.42: Nameplate data for motor# 500BJ2 ..................................................... 127
Table 9.43: Discharge magnitudes for motor# 500BJ2 ..... ...................... ................ 127
Table 9.44: Analysis matrix for motor# 500BJ2 .... ............................................ ..... 127
Table 9.45: Nameplate data for motor# 500BJ3 ..................................................... 128
Table 9.46: Discharge magnitudes for motor# 500BJ3 ........................................... 129
Table 9.47: Analysis matrix for motor# 500BJ3 .... ................................................. 129
Table 9.48: Nameplate data for motor# 950AA3 .................................................... 130
Table 9.49: Discharge magnitudes for motor# 950AA3 ............................. ........... .. 130
Table 9.50: Analysis matrix for motor# 950AA3 ................................................... 131
Table 9.51: Winding data table for machines tested in the plant .............................. 132
Table 10.1: Form coil windings with a resin-rich type impregnation system ............ 135
Table 10.2: Form coil windings with a vpi type impregnation system ..................... 136
Table 10.3: Random wound windings with a dip type impregnation system ............ 137

XVII

© Central University of Technology, Free State

CHAPTER 1 -INTRODUCTION

1.1 Introduction and background

Iscor is a South African company, with its' Flat Steel Products Division based in
Vanderbijlpark. For many years, it has successfully operated a Mechanical Condition
Monitoring Program on all its' critical high voltage motors. This program included
vibration analysis, bearing oil sample analysis, thermal scanning etc. In order to
ascertain the stator winding condition (and reduce the amount of in service winding
failures) of its' high voltage machines, the company has recently introduced an
Electrical Condition Monitoring Program (ECMP).

This program included the following:

• Installation of on-line Partial Discharge (PO) monitoring equipment on all critical
I 1 k V machines.
• Acquisition of a TGA analyzer to carry out in-house testing of 11 kV machines.
• · Acquisition of the MICAA expert system to be used as a database and training tool.

1.2 The problem and its setting

However, the successful completion of the ECMP on 11 kV machines, still excluded six
hundred (also ageing), 3,3 kV machines. All of these machines are an integral part of
the plant operation. More than half of the machines are very critical to the plant
production processes. Failure of these machines, will lead to reduced production or
complete plant shutdown.

A great number of these machines have been in operation for periods exceeding twenty
years, without replacement of the stator winding. Because the operational processes will
naturally lead to insulation degradation, it can be expected that some ofthese machines
would fail shortly.

THlS BOOK IS THE

PRCrE.HTY OF THE

2005 -03- 8-
CEH1kAL UNIVERSITY OF
TECHNOLOGY, FREE STAlt

© Central University of Technology, Free State

1.3 Objective of the research

The purpose of this thesis is to investigate the possibility of using the bus-coupler
method to measure PD on 3,3 kV machines, hence to identify all failure mechanisms
normally associated with high voltage machines.

1.4 Hypothesis

It is possible to identify failure mechanisms on machines operating at 6,6 kV and above

when trending the PD magnitudes, by analysing the graphical representation of PD test
results. This method of evaluation shall be used to determine failure mechanisms for
3,3 kV machines. As 3,3 kV machines have a unique winding and insulation
arrangement, the suitability of these techniques must be investigated to ensure correct
analysis results.

1.5 Research methodology

PD tests will be carried out according to the following conditions:

• Routine testing (after repair of the machine) shall be performed on a test bench,
with the aim of studying the effect of load and thus temperature variance.
• Special tests shall also be conducted on the test bench. These machines shall be
subjected to accelerated ageing practices and dissected.
• Tests shall be carried out on machines operating in a normal plant environment.

1.6 Assumptions

• The study shall assume that PD measurement is possible and effective, using an Iris
Power Engineering PD Analyser and the bus-coupler method of measurement.
• The study shall consider form coil as well as random wound 3,3 kV machines.
• The study shall consider all available 3,3 kV machines (operational and redundant).

© Central University of Technology, Free State

CHAPTER 2 - REVIEW OF THE RELATED LITERATURE

2.1 Introduction

Electrical discharges that do not completely bridges the gap between two conductors are
called partial discharges [1, p. 5]. Partial discharge measurements have been made on
windings of rotating machines for over four decades. Advances made in the last twenty
years in electronic noise discrimination techniques has made it possible for engineers to
successfully distinguish between PO and noise.

Discharges occur mainly in gas filled cavities inside the insulation, and on the surface of
the insulation. The breakdown strength of the cavity depends on its' dimensions and is
governed by the type of gas and the gas pressure in the cavity.

Kreuger (using the a-b-c circuit) has discussed partial discharges occurring in gas filled
cavities within a dielectric extensively [2, p. 3]. The capacitance of a cavity is
represented by a capacitance c ( Figure 2.1 ), which is shunted by a breakdown path. The
capacitance of the dielectric in series with the cavity is represented by a capacitance b.
The sound part of the dielectric is represented by a capacitance a.

If the circuit is energized with an alternating current voltage, recurring discharging

occurs:
• Capacitance c is charged,
• Breakdown voltage of the cavity is reached and discharging occurs,
• Capacitance c is charged again,
• The cavity discharges again, etc.

© Central University of Technology, Free State

 c:::2---- Vc
a

Dielectric

Figure 2.1: Dielectric circuit of insulation

However, recent studies have shown that this approach has limitations that could better
be described using electric field theory [9, pp. 239-241]. The resulting electrical field
within a dielectric material is the vector sum of two components, namely the Laplacian
component and the Poisonian component. The Poisonian induced charge is that
component ofthc induced charge related to the Poisonian field established by the space
charge. The Laplacian induced charge is that component of the induced charge related
to the Laplacian field associated with the change in conducter potential.

2.2 PD sources in rotating machine windings

Rotating machines have numerous potential sites of PD. Machine design, materials of
construction, manufacturing methods, operating conditions and maintenance practices
can profoundly affect the quantity, location, characteristics, evolution and significance
ofPD [1 , pp. 7-8]:
• Ground wall delaminations (Figure 2.2) and cavities that develop as a result of
machine abuse, thermal ageing, bar vibration and PO erosion may exhibit
characteristics that are very different from the characteristics of cavities in new

© Central University of Technology, Free State

 msutauon.
• PD sites may also be present and develop at the interface between the conductors
and the ground wall and between the ground wall and the semi-conducting
treatment (Figure 2.2), on the surfaces of stator winding elements.
• Other potential sites of PO may occur within girth cracks; mechanical disruptions
of insulation caused by overhang heating; sites of impact damage; insulation
fractures and abraded areas.
• Slot discharge sites may occur as the result of certain semi-conductive coating
conditions that either are present when the machine is new, or develop in operation.
These conditions include discontinuities in the semi-conducting slot coating, high
resistivity values of the such that it does not function as intended, porosity,
separations, migration defects and erosion or abrasion defects.
• Slot discharge sites may also caused by or extinguished by certain types of
chemical contamination. It should be noted that because of the wide variation in
stator winding constructions, stator bar vibration might not be indicated by PO
activity in some machines.
• PD sites may develop at the stress control coating at the slot exit as the result of
defects such as electric stress concentrations at the interface between the semi-
conducting slot coating and the stress control coating, sites of mechanical damage,
or shortened stress control coating.
• PO sites may be present or develop in the stator endwinding beyond the slot
because of chemical contamination, floating metal particles, mechanical damage,
relative movement of end-winding elements and the spacing between components
in the endwinding.
• PD sites external to the stator winding may occur:

0 Near improperly installed RTO cables,

0 On phase connection rings because of vibration, mechanical damage, or

relative movement,

0 Within high- voltage bushings,

0 On surfaces of high-voltage bushings, caused by contamination,

0 On phase leads, bus bars, or connection straps,

© Central University of Technology, Free State

 u w nnm surge capacitors, ana

0 Within isolated phase bus duct.

Wedge

Semi-conducting layer

Grounded stator core

High voltage conductor

Centre filler

Ground wall insulation

Figure 2.2: Insulation composition of a form coil

2.3 Overview of Partial Discharge detection methods

Partial discharges are accompanied by several physical manifestations: Electrical pulse

and resulting radio frequency (RF) pulse, acoustic pulse, light, as well as chemical
reactions within the cooling gases that are either air or hydrogen. The following sub-
clauses are a summary of how some of these manifestations can be measured, as a

© Central University of Technology, Free State

[1 , pp. 9-12].

2.3.1 Electrical pulse sensing

Because PD involves a flow of electrons and ions across a small distance in a finite
period of time, a small current flows every time the PD occurs. The total current will be
governed by the transport of a certain number of Pico coulombs of charge. The current
flow creates a voltage pulse across the impedance ofthe insulation system.

One of the primary means of detecting PD is to measure the small voltage pulse that
accompanies every PD, or the resulting current pulse. These quantities are measured in
circuits remote from the PD. Note that in a typical coil, bar or winding, there may be
hundreds of discharges per second, thus many hundreds of electrical pulses may be
detected each second.

The voltage pulse can be detected by means of high- voltage capacitors, which are
normally connected to the phase terminal or elsewhere in the winding. The capacitor
impedance is high at rated power frequency, but is low at the high-frequency signal of
the PD voltage pulse.

Alternatively a current transformer, with an high frequency rating, can be installed on

the lead that connects the neutral of the machine to the grounding impedance, on the
phase leads or in other suitable locations to detect the pulse currents accompanying the
PD.

The outputs from the capacitors or current transformer are respectively voltage or
current pulses, which can be measured with an oscilloscope, spectrum analyser, or pulse
height analyser.

© Central University of Technology, Free State

2.3.2 Radio frequency radiation sensing

In addition to creating voltage and current pulses within the stator winding, the
discharge spark also creates some RF electromagnetic waves that propagate away from
the discharge site. The electromagnetic disturbance created by a PD has RF components
from 100 kHz to several hundreds of MHz.

AM radios with a suitable antenna can therefore be used to sense that PD activity is
occurring. If a directional RF antenna is used, it is sometimes possible to locate the sites
of PD activity within the stator winding.

2.3.3 Power-factor tip up

Because each PD is accompanied by acoustic and RF emissions as well as light, it

follows that each PD event absorbs a certain amount of energy. The energy dissipated in
the PD pulse must therefore be supplied from the source of power frequency voltage,
and it can be considered as an increase in dielectric loss in the stator winding. Thus, an
indirect means of measuring the total discharge activity in a coil or winding is to
measure the dissipation or power factor of the insulation at low voltage (below the PO
inception voltage) and at high voltage (where the presence of any PD will increase the
dielectric losses).

1
A large power-factor tip--up may be indicative of severe PD activity in the coil, bar,
and winding. However, especially for coils at or bars with lower tip--up, a correlation
between tip--up values and PD activity should not be expected.
Stress control coatings on the end arms of coils or bars can be the cause of increased tip-
up, especially for installed windings, in which it is not practical to use guard electrodes.

1
The power factor at high voltage minus the power factor at low voltage.

© Central University of Technology, Free State

2.3.4 Energy/integrated charge transfer

An alternate power frequency approach to that described earlier is the measurement of

the energy and integrated charge transfer that results from PD activity. These methods,
A and B, are detailed in ASTM 03382-95. In method A, the power loss attributed to the
PD activity is calculated from measurements of capacitance and dissipation factor
obtained using a conventional high- voltage Capacitance Bridge.

2.3.5 Ozone detection

In air-cooled machines, the presence of discharges on the surface of the coils or bars
causes chemical reactions in the adjacent air. One of the by-products of the chemical
reactions is ozone. Ozone is a gas with a characteristic odour. The concentration of the
ozone increases if there is substantial surface PD activity. Internal PD well within the
ground wall insulation or adjacent to the copper conductors in form- windings will not
create measurable ozone.
There are several means of measuring the ozone concentration, including inexpensive
chemical tubes and electronic sensors. The concentration of ozone is affected by the
temperature and humidity of the environment as well as the air- flow rate. It may also be
related to machine load and power factor. The sampling location is critical. Though it
may be possible to detect ozone during off-line testing, it is primarily useful as an on-
line monitoring tool.

2.3.6 Acoustic and ultrasonic detection

Each PD creates a small "shock wave" caused by a rapid increase in temperature of gas
in the immediate vicinity of the PD. This small shock wave in turn creates acoustic
noise. When many PD pulses are occurring on the surface of the stator coils, "frying
bacon," sound results.

The acoustical noise occurs in the frequency range of several hundred Hz to 150 kHz,
with most of the acoustical energy occurring around 40 kHz. Directional microphones

© Central University of Technology, Free State

can be used to measure the PD sound level, as well as to locate where the surface PD
may be occurring. Note that the acoustical noise will not be detected if the PD activity is
within the ground-wall unless the activity is especially great.

The method can also be used in conjunction with fibreglass rods that acts as acoustical
wave-guides and provide electrical isolation between the component being tested and
the detector.

2.3.7 Black-out test

A common means of determining the presence and location of surface discharges is to

energize the coil/bar or winding under conditions of complete darkness and conduct a
visual inspection from a safe distance.

Alternatively, under conditions of reduced light, ultraviolet detection equipment may be

used. In the case of installed windings, the black-out test is primarily useful for
detecting and locating surface discharges that involves the stress control coating, air
gaps associated with the end arms of coils/bars that are subjected to phase-to-phase
voltage, or supports associated with the circuit ring bus.

The blackout test may also be useful for locating girth cracks or slot discharge activity
involving individual coils/bars. Some disassembly may be necessary to facilitate the
visual inspection. A 50 Hz or 60 Hz variable voltage supply is desirable for applying the
test voltage. In order to locate some discharge sources, it will be necessary to be able to
energize one phase at a time with the others grounded.

2.4 Measurement techniques used

2.4.1 PD pulse shape

Partial discharge pulses have an extremely fast rise time and short pulse-width. Most PD
detection devices only detect the initial pulse, which has a rise time of 1-5 ns, with

10

© Central University of Technology, Free State

corresponding frequency ranges of 50-250 MHz [3, p. 23].

2.4.2 PD sensors

In order to detect the PD pulse, a sensor must be installed near the source of the PD. The
sensors used for this research were 80 pF Capacitive Couplers. These couplers block the
50 Hz signal and pass the high frequency PO signal. It is connected to the terminals of
the winding, which is close to the line-endwindings where PO could be expected
[16, p. 7].

2.4.3 Measurement system

The system used for this research made use of electrical pulse sensing, specifically
Directional Time-of-Arrival-Noise Cancellation, and is a product of Iris Power
Engineering of Canada. The analysing instrument is called the TGA-B™ (Turbine
Generator Analyser-Model B).

Figure 2.3 is a graphical representation of a connection configuration for a directional

pulse discrimination system. For this directional installation the machine side coupler
(M) was placed as close as possible to the junction between the line-end coil and the
supply cable or circuit ring bus.

11

© Central University of Technology, Free State

 PD ___. ...__ External noise
r--------------------------,
~ Delay (2m) l~
I

I
80 pF Capacitors I Breaker
I
M s I
I
I
Same length coaxial cable
I
~
I Enclosed box
I
Ll Ll I
I
I
I
- - - - - - - - -,--'---.J...--,-------- _I

Connect to TGA-B and laptop

Figure 2.3: Directional Time-of-Arrival Noise Cancellation method

The second system side coupler (S) was placed two meters away from coupler M. The
coaxial cables that connected the secondary side of the couplers to the Analyser were of
the same length. Calibration involves measuring the delay time 2 • In direclional
installations, the PD signal and the system noise signal arrives at the two couplers from
opposite directions and arrives from the same direction at the end of both coaxial cables.

The TGA-B™ separates the pulses according to the following time-of-arrival criteria:
• L 1 represents the time in nanoseconds that it takes a pulse to travel through the
coaxial cables. As the coaxial cables are the same length, the travel time Ll is equal
from both couplers.
• The TGA-B™ compares the T ime-of-Arrival of pulses at the two couplers in a
phase. If a pulse is first detected at coupler M (closest to the stator winding), the
pulse is assumed to be caused by stator PD and should be counted. However, if a

2
Delay is the time in nanoseconds it takes a fast rising time pulse to travel along a bus between the two
couplers.

12

© Central University of Technology, Free State

 pulse is first detected at couplerS (closest to the power system), the pulse is due to
noise and should be classified as noise.
• Similarly, arcing or discharges that arrive at coupler S and then at coupler M
indicates that noise is occurring within the cable or bus, perhaps from poor
connections or PD, and should be counted and classified as bus noise.

The TGA-B™ compares pulse arrival times from the pair of bus couplers per phase,
automatically determines which pulses are due to PD from the stator and determines the
magnitude, number and phase position of such pulses.

13

© Central University of Technology, Free State

CHAPTER 3- PD CHARACTERISTICS OF FAILURE
MECHANISMS

3.1 Relationship between PD pulse polarity and discharge location

3.1.1 Cavities at the interface between the conductor and the ground-wall
insulation

3
When negative polarity pulses predominate, the source of the PD can be expected to be
at or near the copper conductors (Figure 3.1), and may indicate an incomplete bond
between the insulation and the copper. In the case of multi-turn coils there may be an
inadequate bond between the turn insulation and the ground wall [1 , p. 40].

Copper

(Char.) +PD - -PD

(Char.) +PD > -PD

Groundwall insulation

(Char.) +PD < -PD

Stator core
(Char.)=PD signal characteristic

Figure 3.1: Pulse polarity based on cavity location

3
Negative polarity pulses occur mainly during the positive cycle of the system phase-to-ground voltage
waveform.

14

© Central University of Technology, Free State

Unlike a cavity in the bulk of the insulation, metal and dielectric covered electrodes
bound this defect. The discharge mechanism as discussed in section 2.1 still apply.
However, the system is no longer symmetrical, in the sense that the electrodes are
comprised of dissimilar materials. This asymmetry produces a polarity effect, which
results in the predominance of negative PD pulses. Such a result can be predicted from
gas discharge theory and some consideration of the charge mobility on the electrodes
[5, p. 5].

On the insulating surface, the mobility ofthe positive ions is much lower than that for
negative species. Consequently, when the conductor is at high voltage, PD will occur
preferentially on the positive half-cycle of the phase-to-ground voltage waveform, as
negative species will be pushed out into the gas gap towards the positively charged
insulating surface.

The conductor is at a higher voltage potential than the insulating material surrounding it
during the positive half cycle of the phase-to-ground voltage waveform with the result
that the predominance of negative ions on the conductor surface migrate through the
gap (caused by the void) towards the more positively charged insulation surface.

The negative PD pulses refer to the direction of flow of current, which is negatively
charged ions.

Observation of negative polarity dependence usually indicates that the bond between the
conductor stack and the ground wall insulation is deteriorated.

3.1.2 Cavities near iron core

4
When positive polarity PD pulses predominate in magnitude, the source of the PD

4
Positive polarity PD pulses occur mainly during the negative half-cycle of the system phase-to-ground
voltage waveform.

15

© Central University of Technology, Free State

likely involves the external semi-conducting coating on the slot section or the stress
control coating of the coil. In the case of air-cooled machines, such discharges may be
accompanied by the production of ozone [ l , p. 40].

This phenomenon is a surface discharge, which takes place between the surface of the
stator coil and the iron core. Discharges in the slot can result from two principal
processes. In one mechanism degradation of the semicon coating, due to coil movement
causing abrasion or Jack of adhesion of the semi con coating due to chemical attack, can
result in isolated patches of semicon coating or bare patches of the stator insulation
[5, p. 5].

These areas will tend to charge up and depending upon the dimensions of the gas gap,
can result in a discharge. Alternatively, or in concert with the above mechanism,
excessive bar movement due to weakening of the slot support system can also cause slot
discharge. This particular phenomenon is extremely dangerous for stator insulation.

Again, this geometry is asymmetric and hence a polarity effect will be observed. In this
case there will be a predominance of positive PD pulses. T his is because, unlike the
above situation for the defect at the conductor/ insulation interface, the metallic electrode
is grounded. Consequently, the relatively immobile positive space charge on the surface
of the stator insulation will result in localised breakdown occurring predominantly on
the positive half-cycle.

The iron core is at a higher voltage potential, relative to the insulating material (which
surrounds the conductor) adjacent to it, during the negative half-cycle of the phase-to-
ground voltage waveform, with the result that the mobile negative ions in the iron core
migrate towards the more positively charged insulation material.

3.1.3 Voids in the bulk of the insulation

A partial discharge will occur across a void within the insulation material when both an
over voltage in the void exists and a free electron or ion is present. When the voltage

16

© Central University of Technology, Free State

across the void exceeds the breakdown voltage of that insulation material (which is
some composition of air) the partial discharge occur and the voltage across the gap will
stabilize at a level required to sustain the discharge activity. During this process the
charges within the void will redistribute according to the applied voltage. As the ac
voltage cycle reverses polarity, these charges will cause another over voltage, but in the
opposite polarity, resulting in another partial discharge, but the flow of electric charges
(current) is in the opposite direction. If both sides of the void consist of the same
insulation material, then the charge distribution will be equal during the positive and
negative cycles of the voltage waveform. These partial discharge pulses will clump at
the classic positions for the phase-to-ground dependant pulses, which is negative pulses
at 45° for the positive half-cycle of the phase-to-ground voltage and positive pulses at
225° for the negative half-cycle of the phase-to-ground voltage.

3.1.4 Endwinding discharges

Contamination or inadequate spacing between endwindings of two different phases can

lead to partial discharge in that area. Unlike the previously described discharge pulses
that are phase-to-ground voltage dependant, this discharge mechanism is phase-to-phase
voltage dependant. There is a 30° phase shift between the phase-to-ground voltage and
the phase-to-phase voltage, with the result that the discharge activities will be dominant
at 15° and 75° (45°+ and -30°) and 195° and 255° (225°+ and -30°) when the phase-to-
ground voltage is taken as the reference voltage.

3.2 Load effect

If test data are taken at load conditions that differ by at least 40%, it may be possible to
ascertain the effects of magnetic forces on coil vibration. For loose windings PO can be
extremely load dependant, with the positive PO increasing with the load. This is due to
the increase in magnetic forces (F oo e) causing an increase in coil movement and thus
surface (positive) PO activity. The effect is most significant with loose thermoset
windings such as epoxy-mica insulated windings [1, p. 41][3, p. 63] & [13, p. 3].

17

© Central University of Technology, Free State

3.3 Temperature effect

The operating temperature of the machine can greatly affect the results from a partial
discharge test. Various materials respond differently to changes in temperature
[1, p. 42].

3.3.1 Negative temperature effect

The sizes of voids within a stator winding are usually inversely proportional to the
operating temperature. As the temperature increases the copper and ground wall
material expand, closing voids and thus decreasing PD. The greater the temperature
effect, the more the internal delamination [3, p. 64].

3.3.2 Positive temperature effect

It may also be possible that positive PD actually increases with temperature. This
phenomenon is frequently an indication of deterioration of the semicon/grading coating.
As the temperature of the stator winding increases, the resistance of the coatings
increases, and results in an increase in surface (positive) PD activity [3, p. 64].

3.4 Specific failure mechanisms

The following sub-paragraphs are a discussion of the phase-angles at which discharges

would occur for specific failure mechanisms of machines with a stator voltage of 6,6 kV
and higher.

3.4.1 Thermal deterioration

Thermal deterioration results from operating an insulation system for long periods near
its design maximum, or for shorter periods above the design limit. Its' discharge
position is known as the classical position of PD. In general negative PD pulses
normally occur between ooand 90° of the ac cycle and positive PD occur between 180°

18

© Central University of Technology, Free State

and 270°, while most PD mechanisms will produce a peak in partial discharge activity
at about 45° and 225° [4, p. 4] & [6, pp. 5-8].

Voids are distributed throughout the insulation and may discharge regardless of the
"direction" of electrical stress across them. Therefore, a more or less equal distribution
of positive and negative discharges at the classic position is indicative of general
thermal deterioration or ageing. The extent of the change in PD with temperature, is
dependant on the degree of delamination that may be present. There is little change in
PD with load.

3.4.2 Phase-to-phase PD activity

Several PD sources may be found in the endwinding part of the winding of a rotating
machine. Most of the discharge phenomena experienced on the endwinding, give rise to
surface discharges. Since the fields in the endwinding are phase-to-phase dependent and
the electrical fields in the slot area are phase-to-ground voltage, it is possible to
distinguish between discharge activity occurring in the slot part and the endwinding
part, by using the Pulse Phase Analysis plot. Phase-to-phase dependant PD will be
shifted by± 30° [7, p. 576]. Figure 3.2 and Figure 3.3 could explain this 30° shift in the
phase angle of the discharges [8, p. 17].

19

© Central University of Technology, Free State

 e(B-C)

Figure 3.2: Three- phase vector diagram of a rotating machine

Figure 3.2 shows the classical vector diagram of a three phase rotating machine. Three
vectors, 0A, 0B and eC, electrically rotated 120° apart, represents the line to ground
voltages of phases A, B and C. The phase-to-phase dependant voltages are represented
by the vectors e(A-B), e{B-C) and e(C-A). By shifting the phase-to-phase vectors to
originate in point 0 , and by concentrating on phase vectors related to phase-A, Figure
3.3 may be created.

Figure 3.3 shows the electrical field between phases C and A in the endwinding area,
represented by vector e(C-A), to be shifted +30° from the phase-to-ground field in the
slot of phase A, represented by vector 0A. The electrical field between phases B and A,
represented by vector 0(A-B), is shifted -30° from eA.

20

© Central University of Technology, Free State

 , .; '
,·
,·
,·
+ 3o_ ;~ ·' ·

Figure 3.3: Multiple vector diagram

3.4.3 Loose Coils

Unattended loose coils will lead to abrasion of the surface coatings of the coil. Damaged
surface coatings may lead to discharges in the slot. As a result, discharge that occur
from loose coils are predominantly surface type PO within the slot portion of the core
and therefore positive and centred at 225 °. If the stator coils become loose in the slot,
the positive polarity PO pulses can be expected to have at least twice the magnitude and
ten times the repetition rate of the negative polarity pulses [ 1, p. 40]. The condition is
more pronounced during on- line tests at high load. Loose coils have a negative
temperature effect.

3.4.4 Electrical slot discharge

Slot discharge is the term given to discharges that occur between the surface of the coil
and the stator iron . The PO pattern for slot discharge is similar to loose coils, with
positive PO at 225° predominating with a negative temperature effect. There is no
noticeable load effect [3 , p. 70].
-
THIS BOOK IS iHE J 1
21
PROPERTY OF THE
2005 -03- 8-
CENTRAL UNrv't:RStTY OF
TECHNOL~ F~2!ATE I

© Central University of Technology, Free State

3.4.5 Inadequate spacing between coils

This source of PD, results in activity that is phase-to-phase dependent and therefore 30°
shifted from the classic positions. Since this activity is frequently isolated to a specific
area of the winding, the PD pattern may reveal which phases are involved . This is only
possible if the two affected phases both have detectable endwinding activity and their
respective 30° phase shifts correspond to what would be expected according to the
machine rotation. Since the PD may occur between the top and bottom coil in a slot,
visual verification ofthe activity may be difficult [3 , p. 70].

3.4.6 Improper impregnation

When resin, tapes impregnation processes and other factors come into play during the
winding manufacturing, voids may be left entrapped within the winding. These voids
are scattered throughout the insulation without dominance of voids at either the copper
or the core. There is no noticeable polarity predominance ofthe PD activity centered at
45° and 225°. This mechanism has a negative temperature effect but no changes with
load [3, p. 70].

3.4.7 Semicon/grading coating interface deterioration

PD that occurs at the semicon/grading coating interface, is surface type activity that is
phase-to-ground voltage dependant. The activity is predominantly positive and centered
at 225°. The materials involved in this area, are primarily conductive by design and
conductivity changes with temperature. Therefore, an increase in temperature can lead
to an increase in PD activity. If a PD pattern is predominantly positive, centered at 225 °,
and increases with temperature, it is most likely from the semicon/grading coating
interface deterioration [3, p. 71].

22

© Central University of Technology, Free State

CHAPTER 4- INTERPRETING TGA RESULTS

The TGA software has been specially designed to facilitate interpreting the partial
discharge activity in the stator winding, i.e. determining the condition of the stator
winding insulation [6, pp. 5-4]. Since the trend in PD activity over time, and the relative
activity between identical machines is the key to interpreting results, special plots have
been created.

4.1 PD view software

The PD View software contains the following two standard graphical presentations of
the PD data captured:

4.1.1 Pulse height analysis

The main display presented by the PD View software, after completion of each PD test
per phase, shows 2x two-dimensional plots (Figure 4.1 ).

NQN•:251& NQN.-:2118 QM+ : 14~ QM-:1185 NQ+ : 1~G NQN-:1812 QM+:ee2. QM-:1000

Uni.t PD Noise
.,.
I WOO
"'""'1

~
';
·-I
..
~
i
I

.oooJ
!!
...~
g
..
u

g
•
~ l~
10 -j
I
I . :'\,

.,~
j
N! G
i....
0

g
~
: 8 G

1
0

-PO
1000
·-""""
lUQDJ. tude
:\

:1000
(aV}
--
.... !500
'"""
No.i.-
110D .4!000

Voagn:i.t- (.aV)
250t) 3GDO .....

Figure 4.1: Pulse height analysis of PD

Each of these plots is referred to as a pulse height analysis. The plots show the number

23

© Central University of Technology, Free State

of partial discharges per second (vertical scale), versus the magnitude or height of the
pulses (horizontal scale), as recorded by the TGA during the most recent test on a
specific coupler.

The left plot is the pulse height analysis for all the partial discharge activity in the
indicated phase of the winding. The right plot shows the total electrical noise from the
power system.

Two lines are plotted on each pulse height analysis graph. One line indicates the partial
discharge activity from positive partial discharge pulse. The other line is the negative
partial discharge activity.

Qmax (QM) is called the peak PD magnitude - it is a statistical value, defined as the
magnitude corresponding to a partial discharge repetition rate of 10 pulses per second.
Qmax relates to how severe the deterioration is in the worst spot of the winding.

NQN is called the total PD activity - it is another statistical value, which is a normalised
quantity number, which is proportional to the total amount of deterioration monitored
and is similar to the power factor tip-up test.

Qmax indicates PO at the worst place whilst NQN indicates how widespread the PD
activities are.

Polarity predominance is present when there is a clear separation of the positive and
negative graphs or a ratio of +Qmax/-Qmax > 1.5 or -Qmax/+Qmax > 1.5.

4.1.2 Pulse phase analysis

The second type of plot (Figure 4.2) is three-dimensional. These plots show the number
(vertical scale) and magnitude (scale coming out of the page) of the PD versus the ac
phase angle (horizontal scale).

24

© Central University of Technology, Free State

 I i
3
: i..
I: §
l
... s-
1
~ 4
,e

Figure 4.2: Pulse phase analysis ofPD

During data collection, each cycle is divided into 100 phase windows to enable
displaying of data relative to the specific phase-to-ground voltage reference.

4.2 Advance view software

The Advance View data contains a variety of plots and allows for data manipulation,
which can enhance PD interpretation. For this thesis, only the Polar plot and the Linear
Pulse Density plot were considered.

4.2.1 Polar plot

The Pulse Phase data can with the help of the Advance View software be displayed as a
polar plot (Figure 4.3). This makes the recognition of the phase angle of the discharges
much easier. Discharge angles can also be measured more accurately.

The classical pulse positions are at 45° and 225°. Phase-to-phase PD activities are
usually 30° shifted from the classical positions. Pulses at phase-to-ground zero
crossings, oo or 180° are usually from a source that is affected by mechanical vibration,
such as a loose connection. There is however some controversy about the cause for
discharges at the zero crossings.

25

© Central University of Technology, Free State

 0

[0•]
180

Figure 4.3: Polar plot ofPD

4.2.2 Trend plots

The first comparison made during any test analysis and evaluation is to compare the
results of the current test with any previous test results. If the operating parameters
(load, temperature, voltage, etc.), is the same as those of the previous test, then a direct
comparison can be made between the two test results. If the PD is increasing between
test results, there is most likely a decline in the condition of the stator winding
insulation system (Figure 4.4).

tOO 100
80 -·· r-r-r- 80
1..:.1
,. 60

~-
80 1-
~ 40
20 ~F ' 20
0 " I- - 0
Mar Jun Jut Jan

Figure 4.4: Trend plot ofPD

26

© Central University of Technology, Free State

4.2.3 Linear pulse density plot

The Linear pulse density plot (Figure 4.5) presents PO pulse magnitude, and pulse
repetition rate, as a function of reference phase angle and thus provides a means of
Pulse phase analysis .

-- ,., _I
Phase-'to- Phase Dependent
l l I f

-
.....
/
/
./
PD Activity
.
,,

""
~-

.-
~ • ... .. •• ~

' "' - -
Co
-·- .-- • r- '0
·~ ·~
*"" -
-
--
~ -=:_

'r-- ' L
v
L

I
[ 1 l l p o l - - ~n.PO·A- h ....

-
......
I I I I I

-
Phase-~o Dependent
PD A c tivit:y
-
,..... ::-:.. - /
.. " .. --
~

-·-
0

--- - -
.; ito -:b /
/
~ ..J p. -
---
"~ !I •fo
" ~ •fo

"
'/
/ ~

- [Bipot.ar- -PO-&Ph-. • o•J

-
-- I
Cross Coupled
I 1 1

-
- ""'-
L
PO Activity
/

~
·- .
_,_......
0
. -~
' "·t --- -y L
~
/ - .
...
- ·~
t-- ~
-·~ •~>

"" ~-

- '\ /
/

.......,

--
-~
-- -- v

Figure 4.5: Linear pulse density plot

27

© Central University of Technology, Free State

In pulse phase analysis, the reference voltage usually chosen for a given measurement is
the phase-to-ground voltage of the phase subjected to on-line testing. By creating a
linear pulse density plot for each phase of a given machine, with the reference phase-to-
ground voltage shifted 120° between phases based on phase rotation, the discharge
activity will be present in the time domain. Phase-to-phase PD should then be easily
recognizable. Due to the fact that the phase rotation for the tests conducted for this
research was not always known, linear pulse density plots for both A-B-C and A-C-B
rotations were included where possible.

28

© Central University of Technology, Free State

CHAPTER 5- COIL CONSTRUCTION AND INSULATING
SYSTEMS

5.1 Coil construction

5.1.1 Form wound windings

Form wound windings (Figure 5.1) consist of preformed square conductors, with
multiple insulation layers. The bare conductor strands are normally covered with an
insulating film to serve as strand insulation. A certain amount of strands are then
bundled together and insulated to provide dedicated tum insulation. The turns are again
bound together by insulation that provides the ground wall insulation. All of these sub-
parts of the insulation system will contain Mica in some or other form.

Mica is a mineral silicate, appearing in nature in a form that can be split into ever-
thinner sheets. It is the best insulating material found. All quality insulating systems for
medium-voltage motor coils contains Mica and usually fibreglass, since neither material
is damaged by Partial Discharges from voltage stress.

The slot portion of the coil is normally taped (or painted) with a semi-conductive
material that grounds the coil in the slot [II, p. 6]. It is important that the resistivity
values are within the specific band for the motor operation conditions. The coil must
thus provide a low-resistance connection between the coil and the stator slot to prevent
electrical discharge.

With the objective of controlling the stress voltage at the end of the core, a painting (or
tape) of silicon carbide is normally applied on the ground wall insulation, overlapping
the semicon [11 , p. 6] & [12, p. 1]. This non-linear grading coating, allows the voltage
on the surface of the coil in the endwinding to gradually taper off to the minimal voltage
at the semi-conductive coating, thus eliminating discharge at the semi-conductive
coating.

29

© Central University of Technology, Free State

 Wedge

Semi-conducting layer

Grounded stator core

High voltage conductor

Centre filler

Ground wall insulation

Turn insulation

Strand insulation

Figure 5.1: Construction of a Form coil

5.1.2 Random wound windings

In contrast with form wound windings, random wound windings (Figure 5.2) have less
turn insulation (enamel coating), irregular turn arrangements in slot (hence the name
"random") and relatively large and frequent air gaps between the turns/strands are more
difficult to fill with resin [1 0, p. 3].

30

© Central University of Technology, Free State

 U-Shape wedge

Slot Insulation

Middle wedge

Magnet wires

Core area

Figure 5.2: Construction of a Random wound coil

5.2 Insulating Systems

5.2.1 Dip

This process is normally used for random wound machines. The machines are dipped
into an insulating varnish consisting of resinous material and a thinner. The thinner
reduces the viscosity of the resinous material to improve its coating and impregnation
capabilities. During the baking cure of the varnish, the thinner, which is an aromatic,
evaporates, leaving a tough insulating film that improves the dielectric, mechanical and
moisture resistance. However, when the varnish evaporates, voids in the insulation
remain. These voids can allow partial discharges to develop, which can then result in
coil failure .

5.2.2 Vacuum pressure impregnation

This is currently the most used impregnation system. The great advantage of the VPI
system is the removal of all the air from the insulation layers during the vacuum cycle.
All air spaces are filled with resin as it is introduced into the tank to flood the winding.
Pressure is introduced to force the resin into all unfilled spaces in the insulation and coil
structure. The pressure is also used to return the excess resin to the storage tank and the

31

© Central University of Technology, Free State

coils, now filled with resin, are cured at an elevated temperature in an oven.

5.2.3 Resin-rich (B-stage) system

An alternative to the VPI system is the resin-rich insulation system. The Mica tapes are
made with partially cured (or B-stage) tapes. The tapes contains a surplus of resin,
hence the name Resin-Rich [ 14, p. 211].

Coils manufactured with the Resin-Rich system are cured in a hot press to
manufacturing tolerances. The temperature of the press is hot enough to cause the resin
to flow, hopefully filling all air spaces to eliminate voids or air pockets in the coils.
Excess resin usually flows axially into the end-winding region of the coil.

One advantage of the Resin-Rich system is that the resin viscosity needed for good
impregnation is not a factor in the design of the insulation system.

32

© Central University of Technology, Free State

CHAPTER 6- METHODS AND TECHNIQUES

6.1 Devising a method of testing 3,3 kV machines for research purposes

An investigation into existing literature regarding PO measurement on 3,3 kV machines

have shown that due to the low levels of discharge activity encountered, an instrument
was developed by Iris Power Engineering for continuous monitoring [17, pp. 1-
6)[19, p. 2][20, pp. 1-6] & [18, pp. 1-13] called the Motortrac system. Purchasing a
Motortrac system was not an economically viable option and performing Partial
Discharge testing on 3,3 kV machines (for research purposes) came down to three
possible options:
• Installing PO bus-couplers on all machines earmarked for testing:
0 This idea was rejected outright because of the high cost it would entail. The PO
couplers were very expensive in relation to the machines that they were
intended to protect (especially if there were insufficient prove of their success
on 3,3 kV machines).
• Installing bus-couplers on a machine before testing, and removing it afterwards.
This idea were rejected due to the following time constraints:
0 Time required for installing the couplers before a test and removing them
afterwards (Normally a day).

0 Obtaining down time from the plant for the installation and removal of the
couplers on-site.
• To build a portable PD test kit that could be connected into a circuit, perform tests,
and be removed from the circuit again.

It was decided to proceed with option three.

6.1.1 Constructing a portable test kit to perform temporary PD testing

Portable test kits, which contained two epoxy-mica capacitors (placed two meters apart)
per phase, were designed and constructed by the author. Figure 6. 1 shows the original

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© Central University of Technology, Free State

test kit, which was later redesigned (Figure 6.2) to improve safety and operating
conditions.

Figure 6.1: Original portable test kit Figure 6.2: Improved portable test kit

6.2 Testing techniques

In order to study the effect of load, temperature variance, accelerated ageing and
contaminants on the machines, the following type testing was performed:
• Routine tests were performed on repaired machines at the Test Floor, with the aim
of studying the effect of load and consequent temperature variance.
• Special tests were also performed on redundant machines at the Test Floor. These
machines were subjected to accelerated ageing practices and, in some cases,
dissected.
• Machines, operating under normal operating conditions, were also tested on-site.

6.2.1 Routine PD testing at the Test Floor

6.2.1.1 Testing procedures

The machine is connected to a hydraulic dynamometer, and taken through the following
testing cycles as indicated in Table 6.1 to determine any possible failure mechanism :

34

© Central University of Technology, Free State

Table 6.1: Testing cycles to determine possible failure mechanisms

Test Test type Test procedure5 Purpose of test

cycle
1 Start-up test at no- Measure PD while the To determine the base PD,
load. stator winding is still mainly caused by applied
cold. voltage, ofthe machine.
2 Full load test at Measure PD while the This is PD caused by the
cold conditions. machine is 100% loaded applied voltage as well as
and the stator winding the increase in load. A
temperature is still below substantial increase in PD
35°C. will be the first indication
of possible loose coils.
3 Full load test at hot Measure PD while the To measure the PD at
conditions. machine is 100% loaded normal operating
and the stator winding conditions.
temperature is above
70°C.
4 No load test at hot Measure PD with the If the PD magnitude
conditions. load removed but with decreases it could indicate
the stator winding possible movement of coils.
temperature still above
70°C.

6.2.2 Special PD testing at the Test Floor

Two redundant 3,3 kV machines were subjected to extreme thermal stresses. These
machines were coupled to a hydraulic dynamometer and overloaded in order to study
the effect of increased temperature and load on the discharge activity.

5
These rules were adhered to as best possible, taking into account the maximum loading capacity of the
Test Floor and the heat dissipation characteristics of the machine under test.

35

© Central University of Technology, Free State

6.2.3 Tests conducted in the plant environment

Some machines in the plant at lscor Flat Steel Products are subjected to severe
environmental and over-load conditions. Several machines were tested to determine the
PD levels of machines under operational conditions.

The following procedures were followed for on-site testing:

• A date is set with the plant for the intended PD testing of a specific machine.
• All the required test equipment (Portable test kit, analyser, computer, etc.) is
transported to the plant.
• The machine is switched off, the required safety procedures are completed and the
portable test kit is connected into the supply circuit.
• The machine is then powered up to normal operating conditions. This sometimes
required that the machine be operated for at least one hour at normal load, in order
to get as close as possible to normal operating temperature.
• PD tests are then performed on all three phases.
• After completion of the test, the test kit is removed from the circuit, and the
machine is reconnected directly to the supply again.

Analysis of machines tested in a plant environment is normally a question of noting the

discharge magnitude at the phase angle and temperature that it occurred, as the
operating conditions can seldom be varied).

6.3 PD analysis method

6.3.1 PD analysis principles for electrical machines with design operating

voltages of 6,6 kV and above

The PD analysis principles for higher voltage machines has been discussed in detail in
CHAPTER 3 - PD CHARACTERISTICS OF FAlLURE MECHANISMS. These

36

© Central University of Technology, Free State

principles will now be used for the analyses of 3,3 kV motors. Two flow charts
summarise these principles where:
• Classic PO is phase-to ground pulses, which occur all along coils as they pass along
the length of the slots in the iron core (slot PO). This type of PO is centred at 45°
for negative pulses and 225° for the positive pulses [3, p. 50].
• Non-classic PD pulses centred at other positions of the phase cycle may be caused
other voltage references [3, p. 50]:
o Phase-to-phase voltage dependant PO pulses will be ± 30° phase shifted from
the classic position.
o Cross-coupling PO activity is high frequency pulses that may capacitively
couple from one phase to another across the endwinding and can be detected
by observing PO pulses shifted ± 60° or 120° from the classic positions.
o Pulses occurring at oo and 180° are usually from a source that is affected by
mechanical vibration, such as a loose connection.

37

© Central University of Technology, Free State

6.3.1.1 Classic PD flowchart [3, p. 59]

Input current PD
levels

Voids near None Internal

copper

Yes
Loose
coils

Yes
Grading

No

Slot Discharge

38

© Central University of Technology, Free State

6.3.1.2 Non-classic PD flowchart [3 , p. 60]

Input current PD
levels

Yes

Yes Phase-to-
phase PD

Cross-coup-
lingPD

Open air
arcing

39

© Central University of Technology, Free State

6.3.2 Analysis Matrix

The aim of the techniques described in 6.1 , is to obtain data that could be successfully
analysed in order to determine developing failure mechanisms experienced by the
machines under test. An analysis matrix (Table 6.2) were compiled by using PO
analysis principles of higher voltage machines to assist in determining areas of
discharge in a stator winding,

Table 6.2: Analysis matrix

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed?
If not, supply reason?
Are any discharges occurring at the classical
discharge position (45°/225°)?
Does this classical PO have polarity
predominance?
Are the negative discharges predominant?
Are the positive discharges predominant?
Is the positive discharges load dependant?
Is the positive discharges temperature dependant?
Is the discharge angle shifted by 30° from the
45 °/225° axis?
Does the two dimensional plot indicate a "hump",
as normally associated with phase-phase PO?
Is the relationship between the affected phases,
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/!20° from the
45°/225° axis?
Are the discharges occurring at the 0°/1 80°?

40 TH\sBOoK IS 'THE_
PROPERTY OF THl:

2005 -03- 8-
CENTRAl UN\VERSITf OF
'TECHNOLOGY. FREE SlATE

© Central University of Technology, Free State

6.3.2.1 Explanation of matrix abbreviations

• Yes - The discharge angle; temperature dependency; load dependency, etc. can
clearly be distinguished from studying the graphs.
• No- The graph does not correspond with the question asked.
• n/a - The question has no relevance to the graph in question.
• n/c - The graph might correspond with the question asked, but without any
certainty.

6.3.3 Discharge Magnitudes

In order to correctly analyse the data gathered it is essential that the discharge
magnitudes, measured at different loads and temperatures, be available. Table 6.3 is an
example of how this data would be presented to assist analysis:

Table 6.3: Discharge magnitudes at different loads and temperatures

Load and temperature Phase-A Phase-B Phase-C

PO measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of the
stator winding at X°C +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
(Temp. for phases A-B-C)
PO measured at xo/o load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of the
stator winding at X°C +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
(Temp. for phases A-B-C)
PD measured at xo/o load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of the
stator winding at x°C +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax

41

© Central University of Technology, Free State

 Table 6.3: (cont.)

Load and temperature Phase-A Phase-D Phase-C

(Temp. for phases A-B-C)
PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of the
stator winding at x°C +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
(Temp. for phases A-B-C)

42

© Central University of Technology, Free State

CHAPTER 7- PD TESTING AT THE TEST FLOOR

7.1 Introduction

PO testing was performed and results analysed on a machine with unknown winding
configuration, random wound machines and form coil wound machines.

7.2 PD test results and analysis data

7.2.1 Winding type: Form coil

7.2.1.1 Impregnation method - unknown insulation system

7.2.1.1.1 Motor# 150XX3

Table 7.1: Nameplate data for motor# 150XX3

Make Power Stator Voltage Stator Current #Poles

TECO 150 kW 3300 v n/a 4-pole

Table 7.2: Discharge magnitudes for motor # 150XX3

Load and temperature Phase-A Phase-B Phase-C

PO measured at no-load, ~NQ -NQN +NQN -NQN +NQN -NQN
with the temperature of 141 74 98 19 29 17
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
21°C, 22°C and 25°C 75 49 83 0 8 9
respectively.
PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the temperature 160 67 126 94 36 14

43

© Central University of Technology, Free State

 Table 7.2: (Cont.)

Load and temperature Phase-A Phase-B Phase-C

of the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
36°C, 32°C and 28°C 95 49 79 71 21 9
respectively.
PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the temperature 363 339 576 348 1751 1539
of the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
58°C, 59°C and 60°C 181 138 235 203 n/a n/a
respectively.
PO measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 280 215 366 310 167 91
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
59°C, 57°C and 56°C 160 121 322 282 0 0
respectively.
(See Appendixes Al-A5, for graphical representation of discharges)

Table 7.3: Analysis matrix for motor # 150XX3

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges occurring at the classical Yes Yes No
discharge position (45°/225°)?
Does this classical PD have polarity No Yes n/c
predominance?
Are the negative discharges predominant? n/a No n/a
Are the positive discharges predominant? n/a Yes n/a
Is the positive discharges load dependant? n/a No n/a
Is the positive discharges temperature n/a Yes n/a
dependant?
Is the discharge angle shifted by 30° from the Yes Yes No

44

© Central University of Technology, Free State

 Table 7.3: (Cont.)
Condition Phase-A Phase-B Phase-C
45°/225° axis?
Does the two dimensional plot indicate a n/c Yes Yes
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, No No No
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No n/c n/c
45°/225° axis?
Are the discharges occurring at the 0°/180°? No No No

Table 7.4: Winding configuration

Winding Impregnation Coils Turns/ Conductor size Slot Con.

type type coil width
Form ? ? ? ? ? ?

Observations

The machine was opened for inspection, and found to have a Form coil winding.

Conclusion
• The majority of the discharges appear to be occurring in the slot on the surface of
the coil.
• There are also signs of phase-to-phase related discharges:
o Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-
phase failure.
o Inadequate spacing/ insulation between coils can lead to discharges between
coils causing a build-up of ozone.

45

© Central University of Technology, Free State

 o It is however not possible to determine ifthis is occurring between coils in the
slot or on the endwinding.

7.2.1.2 Impregnation method: Dip (Isonel)

7.2.1.2.1 Motor# 400BA2

Table 7.5: Nameplate data for motor# 400BA2

Make Power Stator Stator Current Speed

Voltage
English Electric 400 hp 3300V 62A 1474 r/min

Table 7.6: Discharge magnitudes for motor# 400BA2

Load and temperature Phase-A Phase-B Phase-C

PD measured at 125% +NQN -NQN +NQN -NQN '+NQN -NQN
load, with the 47 42 6 3 14 11
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 33°C, 34°C 26 23 4 3 7 6
and 34°C respectively.
(See Appendixes A 77-A81, f or graphical representation of discharges)

Table 7.7: Analysis matrix for motor # 400BA2

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical No No No
discharge position of (45°/225°)?

46

© Central University of Technology, Free State

 Table 7.7: (Cont.)

Condition Phase-A Phase-B Phase-C

Does this classical PD have polarity n/a n/a n/a
predominance?
Are the negative discharges predominant? n/a n/a n/a
Are the positive discharges predominant? n/a n/a n/a
Is the positive discharges load dependant? n/a n/a n/a
Is the positive discharges temperature n/a n/a n/a
dependant?
Is the discharge angle shifted by 30° from the Yes No Yes
45°/225° axis?
Does the two dimensional plot indicate a No No No
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, Yes Yes Yes
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No No No
45°/225° axis?
Are the discharges occurring at the oo/180°? No No No

Table 7.8: Winding configuration for motor # 400BA2

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form coil Dip (Isonel) 36 15 6.15x2.8 9.8 Star

Observation
The machine had been rewound according to the winding data listed in the winding
configuration table.

47

© Central University of Technology, Free State

Conclusion

Discharges are definitely phase-to-phase, and it is affecting all three phases:

o Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-phase
failure.
o Inadequate spacing/ insulation between coils can lead to discharges between coils
causing a build-up of ozone.
o It is however not possible to determine if this is occurring between coils in the slot
or on the endwinding.

48

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7.2.1.3 Impregnation method: Resin rich insulation system

7.2.1.3.1 Motor# 160BF1

Table 7.9: Nameplate data for motor# 160BFI

Make Power Stator Stator Current Speed

Voltage
Siemens 160 kW 3300 v 37 A 1471 r/min

Table 7. 10: Discharge magnitudes for motor# 160BF1

Load and temperature Phase-A Phase-B Phase-C

PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 3 3 5 6 1 6
temperature of the +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
stator winding at 69°C, 0 2 3 3 0 4
68°C and 68°C
respectively.
(See Appendixes All-Al4, for graphical representation ofdischarges)

Table 7.11: Analysis matrix for motor # 160BF 1

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? No No No
If not, supply reason? Magnitude too low

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Table 7. 12: Winding configuration for motor# 160BF1

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form Coil Resin Rich 48 14 4.25x1.96 12.5 Star

Observations

N/A

Conclusion

Discharge magnitudes at I 00% load and temperature are too low to analyse.

7.2.1.3.2 Motor# 160BF3

Table 7.13: Nameplate data for motor # 160BF3

Make Power Stator Stator Current Speed

Voltage
Siemens 160 kW 3300 v 37 A 1471 r/min

Table 7.14: Discharge magnitudes for motor# 160BF3

Load and temperature Phase-A Phase-B Phase-C

PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 5 n/a 12 10 n/a n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 85°C, 85°C 0 0 0 0 0 0
and 83°C respectively.
(See Appendixes Al5-AJ8, for graphical representation of discharges)

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Table 7.15: Analysis matrix for motor # 160BF3

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? No No No
If not, supply reason? Magnitude too low

Table 7.16: Winding configuration for motor# 160BF3

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form Coil Resin Rich 48 14 4.25xl.96 12.5 Star

Observations
Tl-US BOOK IS THE
PROPERTY OF THE
N/a
2005 -03- 8-
Conclusion CENTRAL UNIVERSITY OF
TECHNOLOGY, FREE STATE

Discharge magnitudes at I 00% load and temperature are too low to analyse.

7.2.1.3.3 Motor# 160BF11

Table 7.17: Nameplate data for motor# 160BF11

Make Power Stator Stator Current Speed

Voltage
Siemens 160 kW 3300 v 37 A 1471 r/min

51

·-CENTRAL
. . . . UNIVERSITY OF
TECHNOLOGY, FREE STATE
1 SENTRALE UNIVERSITEIT
·VIR TEGNOLOGIE, VRYSTAAT
© Central University of Technology, Free State
Table 7.18: Discharge magnitudes for motor# 160BF11

Load and temperature Phase-A Phase-B Phase-C

PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the n/a n/a n/a n/a 5 2
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 72°C, 73°C 0 0 0 0 3 0
and 74°C respectively.
(See Appendixes A 19-A21, for graphical representation ofdischarges)

Table 7.19: Analysis matrix for motor# 160BFI1

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? No No No
If not, supply reason? Magnitude too low

Table 7.20: Winding configuration for motor# 160BF11

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form Coil Resin Rich 48 14 4.25x1.96 12.5 Star

Observations

N/a

Conclusion

Discharge magnitudes at I00% load and temperature are too low to analyse.

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7.2.1.3.4 Motor# 200DP2

Table 7.21 : Nameplate data for motor # 200DP2

Make Power Stator Stator Current Speed

Voltage
Siemens 200kW 3300 v 44.5 A 1477 r/min

Table 7.22: Discharge magnitudes for motor# 200DP2

Load and temperature Phase-A Phase-D Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 7 3 7 11 23 2
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
25°C, 26°C and 27°C 5 0 7 10 16 2
respectively.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 23 n/a 19 37 92 n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 40°C, 37°C 0 0 0 32 87 0
and 31 oc respectively.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 28 17 18 22 75 18
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 69°C, 69°C 12 11 14 14 50 12
and 70°C respectively.
PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 20 5 18 22 75 19
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
62°C, 65°C and 68°C 10 4 12 13 50 12
respectively.
(See Appendixes A32-A36, for graphical representation ofdischarges)

53

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Table 7.23: Analysis matrix for motor# 200DP2

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical Yes No No
discharge position of (45°/225°)?
Does this classical PO have polarity Yes n/a n/a
predominance?
Are the negative discharges predominant? No n/a n/a
Are the positive discharges predominant? Yes n/a n/a
Is the positive discharges load dependant? No n/a n/a
Is the positive discharges temperature Yes n/a n/a
dependant?
Is the discharge angle shifted by 30° from the No Yes Yes
45°/225° axis?
Does the two dimensional plot indicate a Yes Yes n/c
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, n/c n/c n/c
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No n/c n/c
45°/225° axis?
Are the discharges occurring at the 0°/180°? No n/c n/c

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Table 7.24: Winding configuration for motor# 200DP2

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form Coil Resin Rich 48 10 2X(3.9X1.3) Star

Observations

• This machine still has its ' original Siemens winding. The winding data could not be
obtained from the manufacturer. The data shown in the winding configuration
column above were obtained from the data sheet of an identical machine.
• The graphical representation of discharge activity for phases-B&C are very
unusual.

Conclusion

Discharges appear to be phase-to-phase related, with the possibility that phases-B&C

are discharging to air.

7.2.1.3.5 Conclusion summary for resin rich motors tested at the Test Floor

• Discharge values are very low.

• Motor # 200DP2 is the only machine with discharge levels that could be analysed
(only phase-to-phase discharges were visible).
• The winding condition of these type of motors could not be determined by means of
PO measurement.

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7.2.1.4 Impregnation method: Vpi insulation system

7.2.1.4.1 Motor# 185CD1

Table 7.25 : Nameplate data for motor# 185CDI

Make Power Stator Stator Current Speed

Voltage
GEC 185 kW 3300 v 39.7 A 1488 r/min

Table 7.26: Discharge magnitudes for motor# 185CDI

Load and temperature Phase-A Phase-B Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 5 5 69 2 I 12
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
27°C, 29°C and 30°C 0 0 0 0 0 0
respectively.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 6 7 71 2 n/a 7
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 41 °C, 43°C 0 0 0 0 0 0
and 45°C respectively.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the n/a 13 57 26 26 4
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 79°C, 80°C 0 0 40 0 29 0
and 82°C respectively.
PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of n/a n/a 54 47 15 16

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 Table 7.26: (Cont.)

Load and temperature Phase-A Phase-B Phase-C

the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
81°C, sooc and 80°C 0 0 17 23 9 10
respectively.
(See Appendixes A27-A31, for graph1cal representatwn of discharges)

Table 7.27: Analysis matrix for motor# 185CD1

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical No Yes No
discharge position of (45°/225°)?
Does this classical PD have polarity No Yes No
predominance?
Are the negative discharges predominant? n/a No n/a
Are the positive discharges predominant? n!a Yes n/a
Is the positive discharges load dependant? n/a No n/a
Is the positive discharges temperature n/a Yes n/a
dependant?
Is the discharge angle shifted by 30° from the n/a No n/a
45°/225° axis?
Does the two dimensional plot indicate a No No No
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, Yes Yes Yes
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No No Yes
45°/225° axis?
Are the discharges occurring at the 0°/180°? Yes No No

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Table 7.28: Winding configuration for motor# 185CDI

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width

Form coil VPI n/a n/a 7.5x2.12 10.6 n/a

Observations
This machine still has its' original GEC winding. The winding data could not be
obtained from the manufacturer. The data shown in the winding configuration column
above, were obtained from the data sheet of an identical machine.

Conclusion
Most ofthe discharge activity is definitely phase-to-phase related (As can be seen from
the LPD plot).
• Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-phase
failure.
• Inadequate spacing! insulation between coils can lead to discharges between coils
causing a build-up of ozone.
• It is however not possible to determine if this is occurring between coils in the slot
or on the endwinding.

7.2.1.4.2 Motor# 220AA5

Table 7.29: Nameplate data for motor# 220AA5

Make Power Stator Stator Current Speed

Voltage
Siemens 220kW 3300 v 49 A 1478 r/min

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© Central University of Technology, Free State

Table 7.30: Discharge magnitudes for motor# 220AA5

Load and temperature Phase-A Phase-B Phase-C

PO measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 1 n/a I n/a 4 5
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
15°C, l5°C and l5°C 0 0 0 0 3 4
respectively.
PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 1 n/a n/a n/a 4 5
temperature ofthe stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 25°C, 23°C 0 0 0 0 3 4
and 20°C respectively.
PO measured at 150% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 9 10 77 66 23 18
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 48°C, 55°C 7 6 25 49 13 12
and 60°C respectively.
(See Appendixes A37-A41,for graphical representation ofdischarges)

Table 7.31: Analysis matrix for motor# 220AA5

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical No Yes n/c
discharge position of(45°/225°)?
Does this classical PO have polarity n/a Yes n/a
predominance?
Are the negative discharges predominant? n/a No n/a
Are the positive discharges predominant? n/a Yes n/a

59

© Central University of Technology, Free State

 Table 7.31: (Cont.)

Condition Phase-A Phase-B Phase-C

Is the positive discharges load dependant? nla No nla
Is the positive discharges temperature nla Yes nla
dependant?
Is the discharge angle shifted by 30° from the No Yes nlc
45°/225° axis?
Does the two dimensional plot indicate a No No No
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, Yes Yes n/c
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/1 20° from the n/c No No
45°/225° axis?
Are the discharges occurring at the 0°/180°? No No Yes

Table 7.32: Winding configuration for motor # 220AA5

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form Coil VPI (Epoxy) 48 10 2x(3.54xl.4) 9.6 Star

Observations

This machine has been rewound with the data indicated in the winding configuration
column.

Conclusion

Discharges appear to be phase-to-phase related.

• Phase-to-phase discharges can occur on the endwinding due to contamination.

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© Central University of Technology, Free State

 Contamination can lead to tracking which will eventually lead to a phase-to-phase
failure.
• Inadequate spacing/ insulation between coils can lead to discharges between coils
causing a build-up of ozone.
• It is however not possible to determine if this is occurring between coils in the slot
or on the endwinding.

7.2.1.4.3 Motor# 250BB4

Table 7.33: Nameplate data for motor# 250 BB4

Make Power Stator Stator Current Speed

Voltage
AEI 250 hp 3300 v 40.4 A 1470 r/min

Table 7.34: Discharge magnitudes for motor# 250BB4

Load and temperature Phase-A Phase-B Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 4 4 n/a n/a 5 n/a
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
20°C, 19°C and 20°C 3 0 0 0 4 0
respectively.
PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 4 3 5 n/a 6 1
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 30°C, 26°C 0 0 5 0 5 0
and 24°C respectively.
PD measured at 150% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 10 9 68 60 28 16

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 Table 7.34: (Cont.)

Load and temperature Phase-A Phase-B Phase-C

temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 51 °C, 59°C 6 5 25 28 18 12
and 53°C respectively.
(See Appendixes A47-A51, fo r graphical representation ofdischarges)

Table 7.35: Analysis matrix for motor# 250BB4

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical No No Yes
discharge position of (45°/225°)?
Does this classical PO have polarity n/a n/a Yes
predominance?
Are the negative discharges predominant? n/a n/a No
Are the positive discharges predominant? n/a n/a Yes
Is the positive discharges load dependant? n/a n/a No
Is the positive these discharges temperature n/a n/a Yes
dependant?
Is the discharge angle shifted by 30° from the Yes Yes No
45°/225° axis?
Does the two dimensional plot indicate a No No No
"hump", as normally associated with phase-
phase PO?
Is the relationship between the affected phases, No No No
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/1 20° from the No No No
45°/225° axis?
Are the discharges occurring at the 0°/180°? No No No

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© Central University of Technology, Free State

Table 7.36: Winding configuration for motor # 250BB4

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form Coil VPI 60 14 2.33x3.55 1l.l n/a

Observations

The machine had been rewound according to the winding data listed in the winding
configuration table.

Conclusion

Discharges appears to be phase-phase related, with some possible slot discharge.

• Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-phase
failure .
• Inadequate spacing/ insulation between coils can lead to discharges between coils
causing a build-up of ozone.
• It is however not possible to determine ifthis is occurring between coils in the slot
or on the endwinding.

7.2.1.4.4 Motor# 300AA3

Table 7.37: Nameplate data for motor # 300AA3

Make Power Stator Stator Current Speed

Voltage
GEC 300 kW 3300 v 66A 1482 r/min

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© Central University of Technology, Free State

Table 7.38: Discharge magnitudes for motor# 300AA3

Load and temperature Phase-A Phase-B Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 18 12 n/a 2 1 2
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
l8°C, 2l°C and 22°C 11 9 0 2 0 2
respectively.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 28 14 n/a n/a 13 5
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 23°C, 23°C 17 8 0 0 9 4
and 23°C respectively.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 137 143 27 12 14 21
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at x 0 C. 39 73 8 6 9 16
PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 52 61 5 4 18 18
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
X°C. 37 38 5 0 8 5
(See Appendixes A57-A61, for graphical representation ofdischarges)

Table 7.39: Analysis matrix for motor # 300AA3

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical Yes No No
discharge position of ( 45°/225°)?
Does this classical PD have polarity Yes n/a n/a

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 Table 7.39: (Cont.)

Condition Phase-A Phase-B Phase-C

predominance?
Are the negative discharges predominant? Yes n/a n/a
Are the positive discharges predominant? No nla n/a
Is the positive discharges load dependant? n/c n/a n/a
Is the positive discharges temperature Yes n/a n/a
dependant?
Is the discharge angle shifted by 30° from the n/c No No
45°/225° axis?
Does the two dimensional plot indicate a Yes Yes nlc
" hump", as normally associated with phase-
phase PO?
Is the relationship between the affected phases, Yes Yes Yes
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/ 120° from the No Yes No
45 °/225° axis?
Are the discharges occurring at the 0°/180°? No No Yes

Table 7.40: Winding configuration for motor# 300AA3

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form coil VPI 60 8 6.76x2.52 10.4 Star

Observations

• The machine was not fitted with temperature sensors. Temperature readings were
measured externally.
• This machine still has its' original GEC winding. The winding data could not be
obtained from the manufacturer. The data shown in the winding configuration

65

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 column above, were obtained from the data sheet of an identical machine.

Conclusion

Most of the discharge activity is definitely phase-to-phase related (As can be seen from
the LPD plot). All three phases are discharging to each other, with some cross-coupling.
• Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-phase
failure.
• Inadequate spacing/ insulation between coils can lead to discharges between coils
causing a build-up of ozone.
• It is however not possible to determine if this is occurring between coils in the slot
or on the endwinding.

7.2.1.4.5 Motor# 305AA2

Table 7.41: Nameplate data for motor# 305AA2

Make Power Stator Stator Current Speed

Voltage
GEC 380 kW 3300 v 66 A 1482 r/min

Table 7.42: Discharge magnitudes for motor# 305AA2

Load and temperature Phase-A Phase-B Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 83 144 222 163 431 317
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
X°C. 53 86 II 0 83 206 157
PD measured at IOO% +NQN -NQN +NQN -NQN +NQN -NQN

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 Table 7.42: (Cont.)

Load and temperature Phase-A Phase-B Phase-C

load, with the
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at x°C.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 122 220 445 314 787 463
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at x°C. 58 94 211 143 390 234
PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
X°C .
(See Appendixes A62-A66, for graphical representation of discharges)

Table 7.43: Analysis matrix for motor# 305AA2

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical No Yes Yes
discharge position of(45°/225°)?
Does this classical PO have polarity n/a Yes Yes
predominance?
Are the negative discharges predominant? n/a No No
Are the positive discharges predominant? n/a Yes Yes
Is the positive discharges load dependant? n/a n/c n/c
Is the positive discharges temperature n/a Yes Yes
dependant?
Is the discharge angle shifted by 30° from the No n/c No
45°/225° axis?

67

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 Table 7.43: (Cont.)

Condition Phase-A Phase-B Phase-C

Does the two dimensional plot indicate a No No No
"hump", as normally associated with phase-
phase PO?
Is the relationship between the affected phases, Yes Yes Yes
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the Yes No No
45°/225° axis?
Are the discharges occurring at the 0°/180°? No No No

Table 7.44: Winding configuration for motor# 305AA2

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form coil VPI 72 6 4(3.98x2) 11.9 Star

Observations

• The machine had been rewound according to the winding data listed in the winding
configuration table.
• Temperature was not measured during the test. It is however a logical deduction
that the temperature would have risen after the machine was under load for 20
minutes.

Conclusion

The bulk of the discharges appear to be occurring in the slot portion, on the surface of
the coil, with some discharging phase-to-phase.

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7.2.1.4.6 Motor# 380AB1

Introduction

Motor# 380AB 1 is the primary driver for a Coal Crusher at the Coal Plant. The
machine was tested in the plant on 91h February 2002. Analysis of the graphical
representation of the discharges indicated possible end-winding discharge between
phase-B and phase-C (See Appendix C35). A bearing failure caused the machine to be
removed from service and dismantled at Iscor's Electrical Workshop. Figure 7.1 shows
what the machine looked like after dismantling.

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Figure 7.1: End-winding of motor# 380AB 1

The motor was severely contaminated with carbon dust. The bearing failure caused the
rotor to rub, damaging parts of the stator insulation.

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The machine was cleaned and tested at the Test Floor with the following results :

Table 7.45: Nameplate data for motor# 380AB1

Make Power Stator Stator Current Speed

Voltage
GEC 380Kw 3300V 66A 1482 r/min

Table 7.46: Discharge magnitudes for motor# 380AB 1

Load and temperature Phase-A Phase-B Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 158 135 141 132 216 151
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
28°C, 28°C and 28°C 74 68 93 89 57 76
respectively.
PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 398 292 234 203 290 166
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 48°C, 41 oc 192 142 123 94 148 123
and 36°C respectively.
PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 489 345 836 472 893 667
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 71°C, 73°C 236 180 559 375 455 330
and 73°C respectively.
PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of n/a n/a n/a n/a n/a n/a
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
X°C. n/a n/a n/a n/a n/a n/a
(See Appendixes A67-A 71, for graphical representation ofdischarges)

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Table 7.47: Analysis matrix for motor# 380AB1

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical Yes Yes Yes
discharge position of (45°/225°)?
Does this classical PO have polarity Yes Yes Yes
predominance?
Are the negative discharges predominant? No No No
Are the positive discharges predominant? Yes Yes Yes
Is the positive discharges load dependant? n/c n/c n/c
Is the positive discharges temperature Yes Yes Yes
dependant?
Is the discharge angle shifted by 30° from the Yes Yes Yes
45°/225° axis?
Does the two dimensional plot indicate a No No No
"hump", as normally associated with phase-
phase PO?
Is the relationship between the affected phases, No No No
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/ 120° from the No No No
45°/225° axis?
Are the discharges occurring at the 0°/ 180°? No No No

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Table 7.48: Winding configuration for motor# 380AB 1

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form coil VPI 72 6 8x2x2(top) 11.9 Star

Observations

The positive discharges of phases-B&C are shifted with 30° from the classical position.

Conclusion

• The bulk of the discharges appear to be occurring in the slot portion, with some
discharging phase-to-phase.
• Discharge levels s·e emed to have increased substantially since the previous
measurement in the plant.
• After the machine was cleaned, there was no sign of the endwinding " humps"
normally associated with endwinding contamination.
• Although the LPD plots indicate phase-to-phase discharges, the linear plots do not
show any "humps".

7.2.1.4.7 Motor# 380X.Xl

Table 7.49: Nameplate data for motor# 380XXI

Make Power Stator Voltage Stator Current #Poles

Hertz 380 kW 3300 v n/a 4-pole

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Table 7.50: Discharge magnitudes for motor# 380XX1

Load and temperature Phase-A Phase-B Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 342 406 504 459 51 29
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
25°C, 27°C and 28°C 227 192 306 271 33 25
respectively.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 221 167 537 403 49 28
temperature ofthe stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 41 °C, 37°C 155 112 308 235 29 19
and 33°C respectively.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 240 328 952 795 100 97
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 82°C, 67°C 136 200 540 463 72 56
and 79°C respectively.
PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 235 332 1174 836 101 92
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
77°C, 78°C and 75 °C 154 195 741 571 54 53
respectively.
(See Appendixes A 72-A 76, for graphical representation of discharges)

Table 7.51: Analysis matrix for motor# 380XX1

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a

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 Table 7.51: (Cont.)

Condition Phase-A Phase-B Phase-C

Are any discharges centred at the classical No Yes No
discharge position of (45°/225°)?
Does this classical PD have polarity n/a No n/a
predominance?
Are the negative discharges predominant? n/a No n/a
Are the positive discharges predominant? n/a Yes n/a
Is the positive discharges load dependant? n/a No n/a
Is the positive discharges temperature nla Yes nla
dependant?
Is the discharge angle shifted by 30° from the No Yes No
45°/225° axis?
Does the two dimensional plot indicate a No No No
" hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, Yes Yes No
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No No n/c
45°/225° axis?
Are the discharges occurring at the 0°/180°? Yes No No

Table 7.52: Winding configuration for motor# 380XX1

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form coil VPI 72 7 2(5.2x3) 13 Star

Observations

T he machine was newly manufactured according to the data indicated in the winding

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configuration table.

Conclusion

Discharges are definitely phase-to-phase related. The bulk of the discharges are
occurring between phases-A&B:
• Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-phase
failure.
• Inadequate spacing/ insu lation between coils can lead to discharges between coils
causing a build-up of ozone.
• It is however not possible to determine ifthis is occurring between coils in the slot
or on the endwinding.

7.2.1.4.8 Motor# 400KW GEC

Table 7.53: Nameplate data for motor# 400KW GEC

Make Power Stator Stator Current Speed

Voltage
GEC 400kW 3300 v 85 A 1480 r/min

Table 7.54: Discharge magnitudes for motor# 400KW GEC

Load and temperature Phase-A Phase-B Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 21 64 56 13 69 46
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
41°C. 0 48 0 0 50 42
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 34 24 77 29 94 96

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 Table 7.54: (Cont.)

Load and temperature Phase-A Phase-B Phase-C

temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 53°C, 46°C 34 0 54 0 62 63
and 42°C respectively.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 48 30 118 91 109 79
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 70°C, 74°C 25 8 51 46 66 53
and 80°C respectively.
(See Appendixes A90-A94, for graphical representation ofdischarges)

Table 7.55: Analysis matrix for motor# 400KW GEC

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical Yes Yes Yes
discharge position of (45°/225°)?
Does this classical PD have polarity Yes Yes Yes
predominance?
Are the negative discharges predominant? No No No
Are the positive discharges predominant? Yes Yes Yes
Is the positive discharges load dependant? No No No
Is the positive discharges temperature Yes Yes Yes
dependant?
Is the discharge angle shifted by 30° from the No No No
45°/225° axis?
Does the two dimensional plot indicate a Yes No No
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, No No No

77

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 Table 7.55: (Cont.)

Condition Phase-A Phase-B Phase-C

clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°I 120° from the No No No
45°/225° axis?
Are the discharges occurring at the 0°/l80°? No No No

Table 7.56: Winding configuration for motor# 400KW GEC

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form coil VPI 60 7 7.3x3.35 9.5 n/a

Observation
This machine still has its' original GEC winding. The winding data could not be
obtained from the manufacturer. The data shown in the Winding configuration column
above, were obtained from the data sheet of an identical machine.

Conclusion

Discharges appear to be occurring in the slot portion of the winding.

7.2.1.4.9 Motor# 585AA2

Table 7.57: Nameplate data for motor# 585AA2

Make Power Stator Stator Current Speed

Voltage
Brown Boveri 585 hp 3300 v 95 A 980 r/min

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Table 7.58: Discharge magnitudes for motor# 585AA2

Load and temperature Phase-A Phase-B Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 202 76 152 52 n/a 71
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
26°C, 28°C and 28°C 129 45 84 37 54 35
respectively.
PD measured at 70% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 297 191 179 80 226 148
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 35°C, 40°C 142 68 95 38 117 76
and 43°C respectively.
(See Appendixes A95-A99, for graphical representation ofdischarges)

Table 7.59: Analysis matrix for motor# 585AA2

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical Yes Yes Yes
discharge position of (45°/225°)?
Does this classical PD have polarity Yes Yes Yes
predom inance?
Are the negative discharges predominant? No No No
Are the positive discharges predominant? Yes Yes Yes
Is the positive discharges load dependant? n/a n/a n/a
Is the positive discharges temperature Yes Yes Yes
dependant?
Is the discharge angle shifted by 30° from the Yes Yes Yes
45°/225° axis?

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 Table 7.59: (Cont.)

Condition Phase-A Phase-B Phase-C

Does the two dimensional plot indicate a No No No
"hump", as normally associated with phase-to-
phase PD?
Is the relationship between the affected phases, No No No
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No No No
45°/225° axis?
Are the discharges occurring at the 0°/1 80°? No No No

Table 7.60: Winding configuration for motor# 585AA2

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Form coil VPI 72 16 2(4.8x1.2) n/a n/a

Observation

• Only the positive part of the discharges at full-load, are shifted with 30° from the
classical position.
• The machine had been rewound according to the winding data listed in the winding
configuration table.

Conclusion

The bulk of the discharges appear to be occurring in the slot portion, close to the surface
ofthe coil.

r~·us 8ooi< :s1*l

PROPERTY OF THE

80 2005 -03- 8-
CENTRAL UNIVERSITY OF
TECHNOLO"Y. FRE~AT

© Central University of Technology, Free State

7.2.1.4.10 Conclusion summary for vpi motors tested at the Test Floor

• All the motors tested showed some indication ofPD activity.

• Most machines show signs of phase-to-phase related PD.
• A fair amount of motors show discharges in the slot on the surface of the coil. This
could be due to the absence of semi conducting tape on the coils.
• The PD activity in these motors could be an indication of the condition of the
motor, as far as:
o Slot discharges, and
o Phase-to-phase discharges is concerned.

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7.2.2 Winding type: Random wound

7.2.2.1 Motor# 160BB3

Table 7.61: Nameplate data for motor# l60BB3

Make Power Stator Stator Current Speed

Voltage
AEI 160 kW 3300 v 33 A 1482 r/min

Table 7.62: Discharge magnitudes for motor# 160BB3

Load and temperature Phase-A Phase-B Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 313 354 705 534 191 191
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
24°C, 26°C and 33°C 204 216 332 235 122 142
respectively.
PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 272 272 1041 965 426 301
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 40°C, 39°C 179 192 736 656 175 168
and 35°C respectively.
PO measured at 150% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 272 265 1314 1747 577 388
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 50°C, 60°C 161 143 689 738 275 220
and 58°C respectively.
PO measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of n/a n/a 1420 1533 n/a n/a

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 Table 7.62: (Cont.)

Load and temperature Phase-A Phase-B Phase-C

the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
60°C. n/a n/a 757 530 n/a n/a
(See Appendixes A6-A I 0, for graphical representation ofdischarges)

Table 7.63: Analysis matrix for motor# 160BB3

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical n/c No Yes
discharge position of (45°/225°)?
Does this classical PD have polarity n/a n/a Yes
predominance?
Are the negative discharges predominant? n/a n/a No
Are the positive discharges predominant? n/a n/a Yes
Is the positive discharges load dependant? n/a n/a Yes
Is the positive discharges temperature n/a n/a Yes
dependant?
Is the discharge angle shifted by 30° from the n/a Yes Yes
45°/225° axis?
Does the two dimensional plot indicate a No No No
" hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, No Yes Yes
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/ 120° from the n/c No No
45 °/225° axis?
Are the discharges occurring at the 0°/180°? n/c No No

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Table 7.64: Winding configuration for motor# 160BB3

Winding Impregnation Coils Turns/ Conductor size Slot Con.

type type coil width
Random Dip 60 22 4xl.25 & n/a Star
lxl.35

Observations

• Phase-C experienced a drastic increase in PO between no-load and full-load, with

only a 2°C rise in temperature.
• Discharges occurring at 135° and 315° on phase-A, appears to be cross-coupled
from phases-B & C.

Conclusion

• Most of the discharge activity is definitely phase-to-phase related. The bulk of the
discharges are occurring between phases-B&C, with cross-coupling to phase-A.
o Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-
phase failure .
o Inadequate spacing/ insulation between coils can lead to discharges between
coils causing a build-up of ozone.
o It is however not possible to determine ifthis is occurring between coils in the
slot or on the endwinding.
• Phase-C experienced a sudden increase in positive discharges between no-load and
full-load, which has the appearance of a loose coil. This phenomenon could
however be influenced by the fact that the temperature sensing devices are
positioned per phase and not per slot (It is also uncertain what the discharge activity
of a loose random wound coil, would be) .

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7.2.2.2 Motor# 175BD3

Table 7.65: Nameplate data for motor# 175B03

Make Power Stator Voltage Stator Current Speed

GEC 130 kW 3300 v 29A 1487 r/min

Table 7.66: Discharge magnitudes for motor# 175BD3

Load and temperature Phase-A Phase-D Phase-C

PO measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 991 759 2404 2547 1929 1186
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
22°C, 24°C and 23°C 600 501 1266 1408 1223 738
respectively.
PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 1196 795 2343 2573 2102 1541
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 30°C, 35°C 575 509 1312 1411 1090 828
and 40°C respectively.
PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 515 376 457 434 1300 1156
temperature ofthe stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 95°C, 92°C 391 358 233 257 878 719
and 90°C respectively.
PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 539 542 722 505 1635 1282
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
83°C, 80°C and 75°C 391 384 481 371 955 617
respectively.
(See Appendixes A22-A26, for graphical representation ofdischarges)

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Table 7.67: Analysis matrix for motor# 175BD3

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical Yes Yes Yes
discharge position of (45°/225°)?
Does this classical PD have polarity No No No
predominance?
Are the negative discharges predominant? n/a n/a n/a
Are the positive discharges predominant? n/a n/a n/a
Is the positive discharges load dependant? n/a n/a n/a
Is the positive discharges temperature n/a n/a n/a
dependant?
Is the discharge angle shifted by 30° from the n/c Yes No
45°/225° axis?
Does the two dimensional plot indicate a No No No
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, n/c n/c n/c
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the n/c No No
45°/225° axis?
Are the discharges occurring at the 0°/180°? No Yes No

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Table 7.68: Winding configuration for motor# 175BD3

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Random Dip 30 38 1.5, 1.4, 1.0 n/a f).

Observations

• This machine has been rewound with the data indicated in the winding
configuration column.
• The machine experienced very high discharge levels.

Conclusion

The bulk of the discharges appear to be occurring in the slot portion of the winding,
between the conductors and the core.

7.2.2.3 Motor # 240AB3

Table 7.69: Nameplate data for motor# 240AB3

Make Power Stator Stator Current Speed

Voltage
AEI 240kW 3300 v 48A 1482 r/min

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Table 7.70: Discharge magnitudes for motor# 240AB3

Load and temperature Phase-A Phase-B Phase-C

PO measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 3 I 5 3 13 n/a
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
25°C external. 3 0 3 3 4 4
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 5 4 12 5 2 4
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding not measured. 4 0 10 0 0 0
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 24 25 43 40 49 44
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 43°C 13 12 26 22 26 26
external.
PO measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 25 24 48 49 83 53
the stator winding not +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
measured. 16 14 21 34 47 37
(See Appendixes A42-A46, for graphical representation of discharges)

Table 7. 71: Analysis matrix for motor # 240AB3

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical n/c No n/c
discharge position of (45 °/225°)?

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 Table 7.71: (Cont.)

Condition Phase-A Phase-B Phase-C

Does this classical PO have polarity n/a n/a n/a
predominance?
Are the negative discharges predominant? nla n/a n!a
Are the positive discharges predominant? n/a n/a n/a
Is the positive discharges load dependant? n/a n/a n/a
Is the positive discharges temperature n/a n/a n/a
dependant?
Is the discharge angle shifted by 30° from the No Yes Yes
45°/225° axis?
Does the two dimensional plot indicate a Yes Yes Yes
" hump", as normally associated with phase-
phase PO?
Is the relationship between the affected phases, nlc n/c n/c
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/ 120° from the No No No
45°/225° axis?
Are the discharges occurring at the 0°1180°? No No No

Table 7.72: Winding configuration for motor# 240AB3

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Random Unknown 60 30 2x064 & n/a n/a
2x060

Observations

This machine still has its' original AEI winding. The winding data could not be
obtained from the manufacturer. The data shown in the winding configuration column

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above, were obtained from the data sheet of an identical machine.

Conclusion

Discharge activity appears to be phase-to-phase related.

• Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-phase
failure.
• Inadequate spacing/ insulation between coils can lead to discharges between coils
causing a build-up of ozone.
• It is however not possible to determine ifthis is occurring between coils in the slot
or on the endwinding.

7.2.2.4 Motor # 250BC3

Table 7.73: Nameplate data for motor# 250BC3

Make Power Stator Stator Current Speed

Voltage
Hawker Siddeley 250 hp 3300 v 43.7 A 1488 r/min

Table 7.74: Discharge magnitudes for motor # 250BC3

Load and temperature Phase-A Phase-B Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 8 10 n!a n!a 5 n!a
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
23°C, 24°C and 27°C 0 0 0 0 7 0
respectively.
PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN

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 Table 7.74: (Cont.)

Load and temperature Phase-A Phase-B Phase-C

load, with the I 2 n/a n/a 10 n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 37°C, 34°C 0 0 0 0 12 0
and 32°C respectively.
PD measured at 150% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 62 61 72 86 117 67
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 85°C, 79°C 28 31 35 36 63 43
and 87°C respectively.
(See Appendixes A52-A56, for graphical representation ofdischarges)

Table 7.75: Analysis matrix for motor# 250BC3

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical No Yes No
discharge position of (45°/225°)?
Does this classical PD have polarity n/a No n/a
predominance?
Are the negative discharges predominant? n/a n/a n/a
Are the positive discharges predominant? n/a n/a nla
Is the positive discharges load dependant? nla n/a n/a
Is the positive discharges temperature n/a nla n/a
dependant?
Is the discharge angle shifted by 30° from the No No No
45°/225° axis?
Does the two dimensional plot indicate a No Yes No
"hump", as normally associated with phase-
phase PD?

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 Table 7.75: (Cont.)

Condition Phase-A Phase-B Phase-C

Is the relationship between the affected phases, n/c n/c n/c
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the n/c No n/c
45°/225° axis?
Are the discharges occurring at the 0°/1 80°? No No No

Table 7.76: Winding configuration for motor# 250BC3

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Random Dip 48 11 6xl.7 n/a Star

Observations

This machine still has its' original Hawker Siddeley winding. The winding data could
not be obtained from the manufacturer. The data shown in the winding configuration
column above, were obtained from the data sheet of an identical machine.

Conclusion

• Some discharge activity appears to be phase-to-phase related.

• Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-
phase failure.
• Inadequate spacing/ insulation between coils can lead to discharges between
coils causing a build-up of ozone.
• It is however not possible to determine if this is occurring between coils in the
slot or on the endwinding.
• Discharge patterns appear to be random.

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7.2.2.5 Motor # 400CE1

Table 7.77: Nameplate data for motor# 400CE1

Make Power Stator Stator Current Speed

Voltage
Hawker Siddeley 400 hp 3300 v 80A 738 r/min

Table 7.78: Discharge magnitudes for motor# 400CE1

Load and temperature Phase-A Phase-B Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 170 163 229 225 189 167
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
25°C, 26°C and 27°C 93 93 124 115 93 93
respectively.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 153 157 238 165 112 109
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 30°C, 32°C 53 53 104 89 57 57
and 30°C respectively.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 375 350 1525 1219 n/a n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 51 °C, 51 °C 194 161 915 919 n/a n/a
and 51 oc respectively.
PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 552 412 1826 1508 803 730
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax

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 Table 7.78: (Cont.)

Load and temperature Phase-A Phase-B Phase-C

50°C, 49°C and 47°C 259 231 1022 1033 344 344
respectively.
(See Appendixes A82-A85, for graphical representation ofdischarges)

Table 7.79: Analysis matrix for motor# 400CE1

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical Yes Yes Yes
discharge position of (45°/225°)?
Does this classical PO have polarity Yes Yes Yes
predominance?
Are the negative discharges predominant? No No No
Are the positive discharges predominant? Yes Yes Yes
Is the positive discharges load dependant? n/c n/c n/c
Is the positive discharges temperature Yes Yes Yes
dependant?
Is the discharge angle shifted by 30° from the n/c n/c n/c
45°/225° axis?
Does the two dimensional plot indicate a Yes Yes Yes
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, No No No
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/ 120° from the No No No
45°/225° axis?
Are the discharges occurring at the 0°1180°? No No No

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Table 7.80: Winding configuration for motor# 400CEI

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
Random Dip 36 12 1.6 X I 0 n/a n/a

Observation

• Discharges are occurring around the classical position, with some discharges
possibly 30° shifted.
• The machine had been rewound according to the winding data listed in the winding
configuration table.

Conclusion

The bulk of the discharges appear to be occurring in the slot portion, with some
discharging phase-to-phase.

7.2.2.6 Conclusion summary for random wound motors tested at the Test Floor

• Random wound motors are experiencing very high levels ofPD activity.
• The majority of the discharges are occurring within the coil, possibly between the
conductors and the core and between the individual conductors.
• There are also indications of phase-to-phase discharges.

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7.2.3 Winding type: Unknown

7.2.3.1 Motor # 400CH1

Table 7.81: Nameplate data for motor# 400CH 1

Make Power Stator Stator Current Speed

Voltage
GEC 400kW 3300 v 89A 989 r/min

Table 7.82: Discharge magnitudes for motor# 400CH1

Load and temperature Phase-A Phase-B Phase-C

PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of n/a 2 27 n/a n/a 6
the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
X°C. 0 0 30 0 0 6
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the n/a n/a 29 25 15 16
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 21 °C, 21 oc 0 0 24 24 0 0
and 24°C respectively.
PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 60 49 40 23 36 30
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 34°C, 34°C 34 29 33 0 33 31
and 34°C respectively.
PD measured at no-load, +NQN -NQN +NQN -NQN +NQN -NQN
with the temperature of 96 95 48 33 28 26

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 Table 7.82: (Cont.)

Load and temperature Phase-A Phase-B Phase-C

the stator winding at +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
34°C. 62 57 36 0 31 29
(See Appendixes A86-A89, for graphical representation of discharges)

Table 7.83: Analysis matrix for motor# 400CH1

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical n/c Yes Yes
discharge position of(45°/225°)?
Does this classical PO have polarity n/a No No
predominance?
Are the negative discharges predominant? n/a n/a n/a
Are the positive discharges predominant? n/a n/a n/a
Is the positive discharges load dependant? n/a n/a n/a
Is the positive discharges temperature n/a nla nla
dependant?
Is the discharge angle shifted by 30° from the nlc nlc nlc
45°/225° axis?
Does the two dimensional plot indicate a No No No
"hump", as normally associated with phase-
phase PO?
Is the relationship between the affected phases, No No No
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No No No
45°/225° axis?
Are the discharges occurring at the 0°/180°? No No No

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Table 7.84: Winding configuration for motor# 400CH1

Winding Impregnation Coils Turns/ Conductor Slot Con.

type type coil size width
n/a n/a n/a n/a n/a n/a n/a

Observation

No winding data was available for this machine type.

Conclusion

Discharges appear to be occurring in the slot portion of the winding.

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CHAPTER 8- PD TESTING OF SPECIAL MACHINES

8.1 Introduction

Two redundant 3,3 kV machines were donated to the project by Iscor Flat Steel
Products for the purpose of studying the effect of increased temperature and load on the
discharge activity. To be able to subject these machines to extreme thermal stresses, the
machines were coupled to a hydraulic dynamometer located in the Test Floor and
overloaded.

8.2 Testing of motor# 250BB3

This machine was originally built by AEI, but rewound in February 1999 by an
independent repair facility. It operated for two months in the plant, prior to be
decommissioned.

The machine was subjected to different overload cycles over a period of three days as
displayed in Table 8.1:

Table 8.1: Load cycle for motor # 250BB3

Day 1 - 13/04/1999
Load % Time Temp.(0 C) +NQN -NQN +Qmax -Qmax
100 17:22 28 95 68 47 33
170 21 :31 134 2491 200 1233 0
Day 2 - 14/04/1999
Load% Time Temp.(°C) +NQN -NQN +Qmax -Qmax
100 10:06 31 402 173 194 128
175 11 :30 149 2312 210 1186 223

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 Table 8.1: (Cont.)
Day 3 -15/04/1999
Load% Time Temp.(°C) +NQN -NQN +Qmax -Qmax
100 14:10 33 416 268 267 147
200 14:39 173 2136 229 1075 257
(See Appendixes Bl-B7, for graphical representation of discharges)

Table 8.2: Analysis matrix for motor # 250BB3

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical Yes Yes Yes
discharge position of (45°/225°)?
Does this classical PD have polarity Yes Yes Yes
predominance?
Are the negative discharges predominant? No No No
Are the positive discharges predominant? Yes Yes Yes
Is the positive discharges load dependant? No No No
Is the positive discharges temperature Yes Yes Yes
dependant?
Is the discharge angle shifted by 30° from the n/c n/c n/c
45°/225° axis?
Does the two dimensional plot indicate a No No No
"hump", as normally associated with phase-to-
phase PD?
Is the relationship between the affected phases, No No No
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No No No
45°/225° axis?
Are the discharges occurring at the 0°/180°? No No No

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Physical inspection of the stator winding by means of dissection

After completion of the three-day testing, the machine was dismantled, and the line-end
coils were removed for inspection, which revealed the following:
• The rewind and VPI of this machine was poorly done. There was poor
impregnation of the epoxy and the coils were not manufactured to the correct size.
This resulted in the coils being forced into the slots. Which caused the coils to skew
in the slot (Figure 8.1). It also left gaps (in some areas), of up to 0.8mm between
the coil and the slot surface.
• There was visible black discharge residue on the surface of the slot filler between
the top and bottom coils (Figure 8.2 & Figure 8.3). The discharge area was almost
at the end of the slot.
• The machine was not fitted with neither semicon nor stress grading tapes.

Wedge

Top coil

Bottom coil

Exaggerated clearances

Figure 8.1: Skew coils of motor # 250BB3

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 Figure 8.2: Centre filler for motor Figure 8.3: Enlarged view of centre
# 250BB3 filler

Conclusion

• The machine exhibited a dramatic increase in positive discharges with an increase

in temperature (while the negative discharges showed a marginal increase). This is
a classic example of electrical slot discharge due to the non-existence of the
semi con.
• The phase-to-phase related discharges (as shown by the LPD plot) are substantiated
by the discharge residue on the slot filler (Figure 8.2), indicating that some
discharge has occurred in the slot, between the line-end coil and a coil of another
phase in the same slot.

8.3 Testing of motor # 250CG2

This machine was still fitted with its ' original winding and operated in the plant since
1983. After initial loading of the machine, it was found that phase-B was emitting the
most discharge, and it was decided to focus on this phase.

It was therefore decided to increase the temperature in increments (Table 8.3), while
observing the effect on the PD. The dynamometer experienced difficulty in sufficiently

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overloading the machine to cause excessive temperature rise. To solve this problem the
cooling circuit of the machine was interrupted at 100% load conditions.

Table 8.3: Relationship between PD and temperature of motor# 250CG2

Time Temp.(°C) +NQN -NQN +Qmax -Qmax

20:21 37 34 15 18 10
20:36 47 36 16 21 11
20:52 52 35 22 19 10
21:10 65 43 30 24 12
21:21 70 50 36 25 20
21:29 75 51 41 25 20
21:37 80 55 45 27 23
21:46 85 67 50 32 23
21:55 90 80 61 37 27
22:05 95 172 120 84 55
22:14 100 173 149 79 58
22:24 105 229 171 152 159
22:36 111 237 184 149 79
22:46 115 259 172 168 80
22:57 120 295 211 159 94
23:10 125 289 214 160 94
23:23 130 351 206 184 142
23:38 136 390 211 198 140
23:52 141 433 350 284 258
00:03 145 553 302 353 159
00:19 150 650 391 381 302
00:39 155 577 255 397 141

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Relationship between temperature and discharge activity

As can be seen from Figure 8.4, there is a steady rise in PD activity with an increase in
temperature. Both the positive and negative discharge magnitudes are increasing with
the change in positive discharges being consistently more than the negative, with an
increase in temperature (See Appendixes B8-B22 for graphical representation of
discharges).

Relationship between PD and temperature

~
700
Q,j
"'0 600
.....=
·a~ 500
ell
~ 400
Q,j

ff 300
ell
-= 200
(,1
~

~ 100
0
~'V "~ '0~ 0,~ ~,, ~ :,~ b.'- ~
"'" ~
' ' '
Temperature
~ ~

-+-+NQN - -NQN .....tr- +Qmax ~-Qmax

Figure 8.4: Relationship between PD and temperature

Physical inspection of the stator winding by means of dissection

After completion of the three-day testing, the machine was dismantled and the end-
windings cut off for inspection, which revealed the following:
• The stator winding was well manufactured, with very few cavities in the insulation.
• The endwinding were forced close together (Figure 8.5).

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• Removal of the line-end coils showed discharge activity between one line-end coil
and the phase adjacent to it (Figure 8.6 and Figure 8.7).

Figure 8.5: End-winding of motor# 250CG2

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Figure 8.6: Enlargements of PD activity on line-end coil for motor# 250CG2

Figure 8.7: 30X enlargement ofPD activity on line-end coil of motor# 250CG2

Conclusion

• The machine exhibited an increase in both positive and negative discharges with
increased temperature. This is also electrical slot discharge due to the non-
existence ofthe semicon layer.
• There is physical evidence of phase-to-phase related discharges.

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CHAPTER 9- PD TESTING IN A PLANT ENVIRONMENT

9.1 Introduction

Some machines in the plant at lscor Flat Steel Products are subjected to severe
environmental and over-load conditions. Several machines were tested in order to
determine levels of PD activity that a 3,3 kV machine would experience in a plant
environment under operational conditions.

Figure 9.1 is an example of the inaccessibility of some of the machines that were tested.

Figure 9.1: Motor # 150CL3

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9.2 Plant testing

9.2.1 Motors tested with very low PD values

9.2.1.1 Motor # 150CL2

Table 9.1: Nameplate data for motor# l50CL2

Make Power Stator Stator Current Speed

Voltage
AEI 150 kW 3300 v 31 A 1483 r/min

Table 9.2: Discharge magnitudes for motor# 150CL2

Load and temperature Phase-A Phase-B Phase-C

PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the n/a n/a nla n/a n/a n/a
temperature of the +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
stator winding 0 0 0 0 nla n/a
unknown.
(See Appendrxes CJ-C2, for graphrcal representatwn of drscharges)

9.2.1.2 Motor# 160BF1

Table 9.3: Nameplate data for motor# 160BFI

Make Power Stator Stator Current Speed

Voltage
Siemens 160 kW 3300 v 37 A 1471 r/min

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Table 9.4: Discharge magnitudes for motor# 160BF I

Load and temperature Phase-A Phase-D Phase-C

PD measured at 90 % +NQN -NQN +NQN -NQN +NQN -NQN
load, with the n/a n/a 2 n/a n/a n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 45°C. 0 0 0 0 0 0
(See Appendixes C7, for graphical representation ofdischarges)

9.2.1.3 Motor# 160DF3

Table 9.5: Nameplate data for motor# l60BF3

Make Power Stator Stator Current Speed

Voltage
Siemens 160 kW 3300 v 37 A 1471 r/min

Table 9.6: Discharge magnitudes for motor# 160BF3

Load and temperature Phase-A Phase-D Phase-C

PD measured at 90% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the n/a n/a n/a n/a n/a n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 34°C, 36°C 0 0 0 0 0 0
and 42 oc respectively.
(See Appendixes CJ3, for graphical representation ofdischarges)

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9.1.1.1 Motor # 160BF8

Table 9.7: Nameplate data for motor# 160BF8

Make Power Stator Stator Current Speed

Voltage
Siemens 160 kW 3300 v 37 A 1471 r/min

Table 9.8: Discharge magnitudes for motor# 160BF8

Load and temperature Phase-A Phase-B Phase-C

PD measured at 70% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the n/a n/a n/a n/a n/a n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 30°C. 0 0 0 0 0 0
(See Appendixes C 14, for graphical representation of discharges)

9.2.1.4 Motor# 160BF10

Table 9.9: Nameplate data for motor# 160BF1 0

Make Power Stator Stator Current Speed

Voltage
Siemens 160 kW 3300 v 37 A 1471 r/min

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Table 9.10: Discharge magnitudes for motor# 160BF10

Load and temperature Phase-A Phase-B Phase-C

PO measured at 70% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the n/a n/a n/a n/a n/a n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 54°C. 0 0 0 0 0 0
(See Appendixes C15-C1 7, for graphical representation ofdischarges)

9.2.1.5 Motor# 250BC1

Table 9.11: Nameplate data for motor# 250BC1

Make Power Stator Stator Current Speed

Voltage
Hawker Siddeley 250 hp 3300 v 43.7 A 1488 r/min

Table 9.12: Discharge magnitudes for motor# 250BCI

Load and temperature Phase-A Phase-B Phase-C

PO measured at 70% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the n/a n/a n/a n/a n/a n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 45°C, 48°C 0 0 0 0 0 0
and 51 °C respectively.
(See Appendixes C23, for graphical representation of discharges)

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9.2.1.6 Motor # 250BC2

Table 9.13: Nameplate data for motor# 250BC2

Make Power Stator Stator Current Speed

Voltage
Hawker Siddeley 250 hp 3300 v 43.7 A 1488 r/min

Table 9.14: Discharge magnitudes for motor# 250BC2

Load and temperature Phase-A Phase-B Phase-C

PO measured at 95% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the n/a n/a n/a n/a n/a n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 29°C. 0 0 0 0 0 0
(See Appendixes C24, for graphical representation ofdischarges)

9.2.1.7 Motor # 250BC3

Table 9.15: Nameplate data for motor# 250BC3

Make Power Stator Stator Current Speed

Voltage
Hawker Siddeley 250 hp 3300 v 43.7 A 1488 r/min

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Table 9.16: Discharge magnitudes for motor# 250BC3

Load and temperature Phase-A Phase-B Phase-C

PO measured at 70% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the n/a n/a n/a n/a n/a n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 30°C, 33°C 0 0 0 0 0 0
and 36°C respectively.
(See Appendixes C25, for graphical representation ofdischarges)

9.2.1.8 Motor # 250BC4

Table 9.17: Nameplate data for motor# 250BC4

Make Power Stator Stator Current Speed

Voltage
Hawker Siddeley 250 hp 3300 v 43.7 A 1488 r/min

Table 9.18: Discharge magnitudes for motor # 250BC4

Load and temperature Phase-A Phase-B Phase-C

PD measured at 75% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 4 n/a 8 I 6 n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 53°C, 58°C 3 0 6 0 4 0
and 60°C respectively.
(See Appendixes C26, for graphical representation ofdischarges)

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9.2.1.9 Motor # 435AA3

Table 9.19: Nameplate data for motor# 435AA3

Make Power Stator Stator Cur rent Speed

Voltage
AEI 435 hp 3300 v 68 A 988 r/min

Table 9.20: Discharge magnitudes for motor # 435AA3

Load and temperature Phase-A Phase-B Phase-C

PO measured at 90% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the n/a 2 I 1 I n/a
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 36°C. 0 2 0 0 0 0
(See Appendixes C37-C40, for graphical representation of discharges)

9.2.1.10 Conclusion summary

These motors exhibited no or very low levels ofPD activity.

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9.2.2 Motors tested with significant PD values

9.2.2.1 Motor # 150CL3

Table 9.21: Nameplate data for motor# 150CL3

Make Power Stator Stator Current Speed

Voltage
AEI 150 kW 3300 v 31 A 1483 r/min

Table 9.22: Discharge magnitudes for motor# 150CL3

Load and temperature Phase-A Phase-D Phase-C

PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 26 22 401 434 181 158
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding unknown. 0 0 158 193 100 88
(See Appendixes C3-C6, for graphical representation ofdischarges)

Table 9.23: Analysis matrix for motor# 150CL3

Condition Phase-A Phase-D Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical No No No
discharge position of (45°/225°)?
Does this classical PO have polarity n/a n/a n/a
predominance?
Are the negative discharges predominant? nla n/a nla

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 Table 9.23: (Cont.)

Condition Phase-A Phase-B Phase-C

Are the positive discharges predominant? n/a n/a n/a
Is the discharge angle shifted by 30° from the No Yes Yes
45°/225° axis?
Does the two dimensional plot indicate a Yes Yes n/c
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, Yes Yes Yes
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/ 120° from the No No No
45°/225° axis?
Are the discharges occurring at the 0°/180°? No No n/c

Conclusion

The PD appears to be phase-to-phase related:

• Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-phase
failure.
• Inadequate spacing/ insulation between coils can lead to discharges between coils
causing a build-up of ozone.
• It is however not possible to determine ifthis is occurring between coils in the slot
or on the endwinding.

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9.2.2.2 Motor# 160BF2

Table 9.24: Nameplate data for motor# 160BF2

Make Power Stator Stator Current Speed

Voltage
Siemens 160 kW 3300 v 37 A 1471 r/min

Table 9.25: Discharge magnitudes for motor# 160BF2

Load and temperature Phase-A Phase-B Phase-C

PD measured at 90% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 42 50 41 46 50 31
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 52°C, 55°C 21 25 20 21 42 24
and 56 oc respectively.
(See Appendixes C8-C12, for graphical representation ofdischarges)

'
Table 9.26: Analysis matrix for motor# 160BF2

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical No No Yes
discharge position of (45°/225°)?
Does this classical PD have polarity n/a n/a Yes
predominance?
Are the negative discharges predominant? n/a n/a No
Are the positive discharges predominant? n/a n/a Yes
Is the discharge angle shifted by 30° from the Yes No n/c

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 Table 9.26: (Cont.)

Condition Phase-A Phase-B Phase-C

45°/225° axis?
Does the two dimensional plot indicate a No No n/c
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, Yes Yes Yes
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/ 120° from the No Yes No
45°/225° axis?
Are the discharges occurring at the 0°I 180°? n/c No No

Conclusion

The PD appears to be phase-to-phase related.

• Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-phase
failure.
• Inadequate spacing/ insulation between coils can lead to discharges between coils
causing a build-up of ozone.
• It is however not possible to determine if this is occurring between coils in the slot
or on the endwinding.

9.2.2.3 Motor # 180CC4

Table 9.27: Nameplate data for motor# 180CC4

Make Power Stator Stator Current Speed

Voltage
Harland 180 hp 3300V 29A 980 r/min

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Table 9.28: Discharge magnitudes for motor# 180CC4

Load and temperature Phase-A Phase-B Phase-C

PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 66 38 15 30 21 32
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 28°C. 32 35 12 28 13 12
(See Appendixes C 18-C22, for graphical representation ofdischarges)

Table 9.29: Analysis matrix for motor# 180CC4

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges occurring at the classical No No No
discharge position (45°/225°)?
Does this classical PD have polarity n/a n/a n/a
predominance?
Are the negative discharges predominant? n/a n/a n/a
Are the positive discharges predominant? n/a n/a n/a
Is the discharge angle shifted by 30° from the Yes Yes Yes
45°/225° axis?
Does the two dimensional plot indicate a Yes Yes Yes
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, Yes Yes Yes
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No No No
45 °/225° axis?
Are the discharges occurring at the 0°/180°? No No No

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Conclusion

Phase-to-phase related PD:

• Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-phase
failure.
• Inadequate spacing/ insulation between coils can lead to discharges between coils
causing a build-up of ozone.
• It is however not possible to determine if this is occurring between coils in the slot
or on the endwinding.

9.2.2.4 Motor # 305AA2

Table 9.30: Nameplate data for motor# 305AA2

Make Power Stator Stator Current Speed

Voltage
GEC 380 kW 3300 v 83 A 983 r/min

Table 9.31: Discharge magnitudes for motor# 305AA2

Load and temperature Phase-A Phase-B Phase-C

PO measured at 45% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 140 183 172 232 626 484
temperature ofthe stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 55°C, 51 oc 76 101 121 146 387 289
and 55°C respectively.
(See Appendixes C27-C31, for graphical representation of discharges)

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Table 9.32: Analysis matrix for motor# 305AA2

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical No No Yes
discharge position of (45°/225°)?
Does this classical PO have polarity n/a n/a Yes
predominance?
Are the negative discharges predominant? n/a n/a No
Are the positive discharges predominant? n/a n/a Yes
Is the discharge angle shifted by 30° from the No No No
45°/225° axis?
Does the two dimensional plot indicate a No No No
" hump", as normally associated with phase-
phase PO?
Is the relationship between the affected phases, Yes Yes Yes
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/J 20° from the No No No
45°/225° axis?
Are the discharges occurring at the 0°/180°? Yes No No

Conclusion

Phase-to-phase related PO:

• Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-phase
failure.
• Inadequate spacing/ insulation between coils can lead to discharges between coils
causing a build-up of ozone.

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• It is however not possible to determine if this is occurring between coils in the slot
or on the endwinding.

9.2.2.5 Motor# 380AB1

Table 9.33: Nameplate data for motor# 380AB 1

Make Power Stator Stator Current Speed

Voltage
GEC 380 kW 3300 v 83 A 983 r/min

Table 9.34: Discharge magnitudes for motor# 380AB 1

Load and temperature Phase-A Phase-B Phase-C

PO measured at 65% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 129 118 88 62 150 124
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 61 °C. 71 63 38 30 97 73
(See Appendixes C32-C36, for graphical representation of discharges)

Table 9.35: Analysis matrix for motor# 380AB 1

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical Yes Yes Yes
discharge position of(45°/225°)?
Does this classical PO have polarity No Yes No
predominance?
Are the negative discharges predominant? n/a No n/a

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 Table 9.35: (Cont.)

Condition Phase-A Phase-B Phase-C

Are the positive discharges predominant? n/a Yes n/a
Is the discharge angle shifted by 30° from the No No No
45°/225° axis?
Does the two dimensional plot indicate a No No No
" hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, No No No
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No No No
45°/225° axis?
Are the discharges occurring at the oo/180°? No No No

Conclusion

The bulk of the discharges appear to be occurring in the slot portion of the coil.

9.2.2.6 Motor # 435AA5

Table 9.36: Nameplate data for motor# 435AA5

Make Power Stator Stator Current Speed

Voltage
AEI 435 hp 3300 v 68A 988 r/min

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Table 9.37: Discharge magnitudes for motor# 435AA5

Load and temperature Phase-A Phase-B Phase-C

PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 3 8 17 15 24 15
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 38°C, 40°C 3 6 11 11 14 7
and 40°C respectively.
(See Appendixes C41-C45, for graphical representation ofdischarges)

Table 9.38: Analysis matrix for motor# 435AA5

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical No Yes Yes
discharge position of (45°/225°)?
Does this classical PD have polarity n/a Yes Yes
predominance?
Are the negative discharges predominant? n/a No No
Are the positive discharges predominant? n/a Yes Yes
Is the discharge angle shifted by 30° from the n/a No No
45°/225° axis?
Does the two dimensional plot indicate a No No No
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, n/c n/c n/c
clearly visible on the LPD plot (for the correct
phase rotation)?

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 Table 9.38: (Cont.)

Condition Phase-A Phase-B Phase-C

Are the discharges shifted by 60°/120° from the n/c No No
45°/225° axis?
Are the discharges occurring at the 0°/180°? n/c No No

Conclusion

• The bulk of the discharges appear to be occurring in the slot portion of the coil.
• The LPD plot indicates phase-to-phase related PO between phases-A&C.

9.2.2.7 Motor # 500BJ1

Table 9.39: Nameplate data for motor# 500BJ I

Make Power Stator Stator Current Speed

Voltage
Siemens 500kW 3300 v 114 A 1450 r/min

Table 9.40: Discharge magnitudes for motor# 500BJ 1

Load and temperature Phase-A Phase-B Phase-C

PO measured at 80% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 1025 690 219 333 412 323
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 43°C. 672 442 139 184 236 198
(See Appendixes C46-C50, for graphical representation of discharges)

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Table 9.41: Analysis matrix for motor# 500BJ 1

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical Yes No Yes
discharge position of (45°/225°)?
Does this classical PD have polarity No n/a Yes
predominance?
Are the negative discharges predominant? No n/a No
Are the positive discharges predominant? n/a n/a Yes
Is the discharge angle shifted by 30° from the n/a n/a No
45°/225° axis?
Does the two dimensional plot indicate a n/c No No
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, Yes Yes n/c
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No Yes No
45°/225° axis?
Are the discharges occurring at the 0°/180°? No No No

Conclusion

PD appears to be occurring on the surface of the coil, with some phase-to-phase related
activity. The machine was opened for inspection and the coils were found to be skewed
in the slots, which left 0.5mm cavities between some of the coils and the core.

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9.2.2.8 Motor # 500BJ2

Table 9.42: Nameplate data for motor # 500BJ2

Make Power Stator Stator Current Speed

Voltage
Siemens 500kW 3300 v 114 A 1450 r/min

Table 9.43: Discharge magnitudes for motor# 500BJ2

Load and temperature Phase-A Phase-B Phase-C

PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 34 18 n/a 25 n/a 20
tern perature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 30°C. 23 17 32 24 15 12
(See Appendixes C51-C55, for graphical representation of discharges)

Table 9.44: Analysis matrix for motor# 500BJ2

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical n/c n/c n/c
discharge position of visible on the LPD plot (for
the correct phase rotation)?
Does this classical PD have polarity Yes Yes Yes
predominance?
Are the negative discharges predominant? No No No
Are the positive discharges predominant? Yes Yes Yes

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 Table 9.44: (Cont.)

Condition Phase-A Phase-B Phase-C

Is the discharge angle shifted by 30° from the Yes Yes Yes
45°/225° axis?
Does the two dimensional plot indicate a Yes Yes Yes
" hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, n/c n/c n/c
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No No No
45°/225° axis?
Are the discharges occurring at the 0°/180°? No No No

Conclusion

This machine operates in a very humid environment. The unusual discharge patterns as
well as the "humps" on the 20 plot, indicates possible end-winding discharges.

9.2.2.9 Motor # 500BJ3

Table 9.45: Nameplate data for motor# 500BJ3

Make Power Stator Stator Current Speed

Voltage
Siemens 500kW 3300 v 114 A 1450 r/min

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Table 9.46: Discharge magnitudes for motor# 500BJ3

Load and temperature Phase-A Phase-B Phase-C

PD measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 26 15 39 24 17 7
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 67°C, 63°C 13 7 19 12 7 4
and 60°C respectively.
(See Appendixes C56-C60, for graph1cal representatwn of dtscharges)

Table 9.47: Analysis matrix for motor# 500BJ3

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical Yes Yes Yes
discharge position of (45°/225°)?
Does this classical PO have polarity Yes Yes Yes
predominance?
Are the negative discharges predominant? No No No
Are the positive discharges predominant? Yes Yes Yes
Is the discharge angle shifted by 30° from the Yes Yes Yes
45°/225° axis?
Does the two dimensional plot indicate a No No No
"hump", as normally associated with phase-
phase PO?
Is the relationship between the affected phases, n/c n/c n/c
clearly visible on the LPD plot (for the correct
phase rotation)?

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 Table 9.47: (Cont.)

Condition Phase-A Phase-B Phase-C

Are the discharges shifted by 60°/120° from the No Yes No
45°/225° axis?
Are the discharges occurring at the 0°/180°? No No No

Conclusion

PO appears to be occurring on the surface of the coil.

9.2.2.10 Motor # 950AA3

Table 9.48: Nameplate data for motor# 950AA3

Make Power Stator Stator Current Speed

Voltage
Siemens 950kW 3300 v 200 A 1484 r/min

Table 9.49: Discharge magnitudes for motor# 950AA3

Load and temperature Phase-A Phase-B Phase-C

PO measured at 100% +NQN -NQN +NQN -NQN +NQN -NQN
load, with the 20 29 143 86 17 25
temperature of the stator +Qmax -Qmax +Qmax -Qmax +Qmax -Qmax
winding at 67°C, 80°C II 13 88 57 10 14
and 81 °C respectively.
(See Appendixes C61 -C65, for graphical representatiOn of discharges)

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Table 9.50: Analysis matrix for motor# 950AA3

Condition Phase-A Phase-B Phase-C

Can the graphical data be analysed? Yes Yes Yes
If not, supply reason? n/a
Are any discharges centred at the classical No Yes No
discharge position of (45°/225°)?
Does this classical PD have polarity n/a Yes Yes
predominance?
Are the negative discharges predominant? n/a No n/a
Are the positive discharges predominant? n/a Yes n/a
Is the discharge angle shifted by 30° from the Yes Yes Yes
45°/225° axis?
Does the two dimensional plot indicate a n/c No n/c
"hump", as normally associated with phase-
phase PD?
Is the relationship between the affected phases, Yes Yes Yes
clearly visible on the LPD plot (for the correct
phase rotation)?
Are the discharges shifted by 60°/120° from the No No Yes
45°/225° axis?
Are the discharges occurring at the 0°/1 80°? Yes No No

Conclusion

PD appears to be phase-to-phase related:

• Phase-to-phase discharges can occur on the endwinding due to contamination.
Contamination can lead to tracking which will eventually lead to a phase-to-phase
failure.
• Inadequate spacing/ insulation between coils can lead to discharges between coils

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 causing a build-up of ozone.
• It is however not possible to determine if this is occurring between coils in the slot
or on the endwinding.

9.2.2.11 Conclusion summary for motors tested in the plant

• Motors # 150CC3, 305AA2 and 380AB1 are random wound machines with
extensive PD activity situated within the coil. All these motors have been rewound.
• Motor # 500BJ I is a form coil machine operated in a very humid environment and
is experiencing extensive electrical slot discharge activity.

9.3 Winding data

Table 9.51 summarises the winding data of machines tested in the plant.

Table 9.5 I: Winding data table for machines tested in the plant

Group Winding Impreg- Coils Turns/ Conductor Slot

no type nati9n type coil size width
150CL2 Random Dip 30 20 lxl.6, 1.32 & n/a
2xl.7
150CL3 Random Dip 30 20 Ixl.6, 1.32 & n/a
2x1.7
160BF1 Form coil Resin Rich 48 14 4.25 X 1.96 12.5
160BF2 Form coil Resin Rich 48 14 4.25 X 1.96 12.5
160BF3 Form coil Resin Rich 48 14 4.25 X 1.96 12.5
160BFIO Form coil Resin Rich 48 14 4.25 X 1.96 12.5
180CC4 n/a Dip 90 24 3.35 X 2 12
180CC6 n/a Dip 90 24 3.35 X 2 12
250BCI Random Dip 48 11 6 X 1.7 n/a
250BC2 Random Dip 48 11 6 X 1.7 n/a

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 Table 9.51: (Cont.)

Group Winding Impreg- Coils Turns/ Conductor Slot

no type nation type coil size width
250BC3 Random Dip 48 11 6 X 1.7 n/a
250BC4 Random Dip 48 11 6 X 1.7 n/a
305AA2 Form coil VPI 72 6 3.98x2x2 11.9
380AB1 Form coil VPI 72 6 8x2 11.9
435AA3 Form coil VPI 90 6 5.65 X 2.8 n/a
435AA5 Form coil VPI 90 6 5.65 X 2.8 n/a
500BJ1 Form coil Resin Rich 48 7 5.6 X 2.8 15
500BJ2 Form coil Resin Rich 48 7 5.6 X 2.8 15
500BJ3 Form coil Resin Rich 48 7 5.6 x2.8 15
950AA3 Form coil Resin Rich n/a n/a n/a n/a

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CHAPTER 10- CONCLUSIONS AND RECOMMENDATIONS

10.1 Findings

10.1.1 The relationship between PD magnitudes and type testing

10.1.1.1 Routine PD testing performed at the Test Floor

Of the twenty-one machines tested at the Test Floor, three machines (14%) had no
significant PD activity that could be analyzed. The average maximum Qmax values
(positive or negative) were 271 m V. PD measurements were taken at an average load
and temperature of I 08% and 64°C, respectively.

10.1.1.2 PD testing in a plant environment

Twenty machines were tested in a plant environment. Fifty percent of these machines
had no significant PD discharge activity. The average maximum Qmax values were
158 m V. PD measurements were taken at an average load and temperature of 83% and
45°C, respectively. The disparity in discharge activity between a machine tested at the
Test Floor, and that tested in the plant, could be attributed to the difference in average
load and thus temperature.

10.1.2 Relationship between PD magnitudes and coil construction types

Table I 0.1 summarizes the PD discharge activities measured in motors with form coil
windings with a resin-rich type impregnation system

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Table l 0.1: Form coil windings with a resin-rich type impregnation system

Group Load Temp. +NQN -NQN +Qmax -Qmax Original/

no rewound
160BF1 100% 68 5 6 3 3 Original
160BF2 90% 56 50 31 42 24 Original
160BF3 100% 85 12 10 0 0 Original
160BF8 70% 30 n/a n/a n/a n/a Original
160BFIO 70% 54 n/a n/a n/a n/a Original
160BF11 100% 74 5 2 3 0 Original
200DP2 100% 70 75 18 50 12 Original
500BJ1 80% 43 1025 690 672 442 Original
500BJ2 100% 30 34 18 23 17 Original
500BJ3 100% 63 39 24 19 12 Original
950AA3 100% 80 143 86 88 57 Original

Discharge values for resin-rich type windings are very low. The average PD magnitude
is 95 mY . According to results provided by Iris Power Engineering (15, p. 9], it can be
seen that up to the year 2001, 90% of the 4 kV machines in their database had Qmax
magnitudes of less than 262 m V.

Table l 0.2 summarizes the PD discharge activities measured in motors with form coil
windings with a vpi type impregnation system

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Table I 0.2: Form coil windings with a vpi type impregnation system

Group no Load Temp. +NQN -NQN +Qmax -Qmax Original/

rewound
185CDI 100% 80 57 26 40 0 Original
300AA3 100% n/a 137 143 39 73 Original
400KW 100% 74 118 91 51 46 Original
435AA5 100% 40 24 15 14 7 Original
220AA5 150% 55 77 66 25 49 Rewound
250BB4 150% 59 68 60 25 28 Rewound
305AA2 100% n/a 787 463 390 234 Rewound
380AB1 100% 73 893 667 455 330 Rewound
380XX1 100% 67 952 795 540 463 Rewound
435AA3 90% 36 1 1 0 0 Rewound
585AA2 70% 35 297 191 142 68 Rewound

The average PD magnitude is 178 mV. As can be seen from the column above, most of
the Qmax magnitudes have a value below 262 mY. Only three of the rewound vpi
machines have values exceeding that of the Iris database.

Table 10.3 summarizes the PD discharge activities measured in motors with random
wound windings with a Resin-Rich type impregnation system

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Table 10.3: Random wound windings with a dip type impregnation system

Group no Load Temp. +NQN -NQN +Qmax -Qmax Original/

rewound
150CL2 100% n/a n/a n/a n/a n/a Original
240AB3 100% 43 49 44 26 26 Original
250BC1 70% 48 n/a n/a n/a n/a Original
250BC2 95% 29 n/a n/a n/a n/a Original
250BC3 150% 87 117 67 63 43 Original
250BC4 75% 58 8 l 6 0 Original
l60BB3 150% 60 1314 1747 689 738 Rewound
l75BD3 100% 90 1300 1156 878 719 Rewound
150CL3 100% n/a 401 434 158 193 Rewound
400CE1 100% 57 1525 1219 915 919 Rewound

Discharge values for original random wound dipped machines were very low. Rewound
machines had an average PO magnitude of 682 mV.

10.1.3 Correlation between discharge patterns for 3,3 kV machines and

established failure mechanisms for higher voltage machines

10.1.3.1 Phase-to-phase related discharges

A large number of the machines (46%), which had significant PO to analyse, showed
definite phase-to-phase dependant PO (As can be seen from the LPD plots).

Phase-to-phase related PO would have an expected influence on two failure

mechanisms of3,3 kV machines:
• End-winding contamination
• Inadequate spacing between coils

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Phase-to-phase discharges can also occur between coils in the slot (Also identified
during the dissection of motor# 250BB3).

10.1.3.2 End-winding contamination

End-winding contamination will normally lead to phase-to-phase discharges (As the

end-winding is the knuckle portion of the coil that extends beyond the stator core, and
thus away from earth). As was seen in I 0.1.3 .I , nearly 50% of the discharge activity
analysed, was phase-to-phase related. It is however difficult to determine (with
certainty), if a machine with phase-to-phase discharge activity is suffering from end-
winding contamination.

Motor# 380AB I had the characteristic "hump" associated with end-winding

discharging [3, p. 66] as well as the 30° shift, from the classical position, in discharge
phase angle. Motors # 500BJ2 & 500813 has the same symptoms and operates in a very
humid environment (It drives main water supply pumps, situated two stories below
level, next to the river).

10.1.3.3 Inadequate spacing between coils

Motor# 250CG2 was used for special temperature rise tests at the Test Floor. The
machine was expected to be discharging between phases, due to the close proximity of
the phase to each other on the endwinding.

The phase-to-phase relationship on the LPD plot is not as well recognisable as for some
of the other machines. However, the physical evidence found after the machine was
dissected (Figure 8.6), indicated that the machine was discharging between phases on
the endwinding.

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10.1.3.4 Electrical slot discharge and semicon/grading coating interface
deterioration

More than 80% of the machines tested (with discharge activity) at the Test Floor
experienced an increase in PO activity with an increase in temperature. The majority of
these machines experienced a bigger increase in positive discharges than in negative
discharges, indicating that discharging is occurring on the surface of the coil.

Some of the machines (e.g., 400CE1 , 400KW GEC & 585AA2) are discharging at the
classic phase position, indicating possible slot discharge.

Very few of these machines are fitted with semi con or a grading coating. The increase
in the discharge activity due to an increase in temperature could therefore be attributed
to discharging in the slot due to the absence of a semicon layer.

10.1.3.5 Improper impregnation

In order to determine without a doubt if a winding was improperly impregnated, the

following actions would have to be taken:
• The complete insulating process would have to be inspected for; compatibility of
resins and tapes, adherence to minimum requirements for vacuum and pressure
cycles where applicable.
• The winding would have to be dissected.

It would be difficult to determine if a machine had high PD due to improper

impregnation, if the machine were tested after it was operating for more than a year with
a new winding. PD activity could have increased due to thermal deterioration. Motors #
305AA2 and 380AB 1 were tested approximately two weeks after it was rewound. There
appear to be limited discharging occurring between phases, with the PD activity mainly
centred at the classic position \ 45°/225°). The cavities causing these discharges could
possible be attributed to improper impregnation.

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10.1.3.6 Loose coils

None of the machines showed any of the expected changes of discharge activity with
load.

10.1.3.7 Thermal deterioration

Thermal deterioration is such a long-term failure, that it can normally not be detected in
a period of two years.

10.2 Conclusions

• Partial discharge measurement techniques can be used to diagnose certain faults on

3,3 kV machines. It is more effective to determine the condition of random wound
motors than form coil motors.
• 3,3 kV machines, under normal operating conditions, experience partial discharge
levels that are much lower than that experienced by higher voltage machines.
• The majority of discharge activity in 3,3 kV machines appears to be phase-to-phase
related.
• In certain cases (when phase-to-phase discharge is not totally predominant) end-
winding contamination, electrical slot discharge and inadequate spacing between
coils could be detected.
o There is no evidence that loose coils, thermal deterioration and improper
impregnation can be detected on 3,3 kV motors by using PO measurement
techniques.
• Resin-rich machines experience the lowest levels of PD.
• Random wound machines experienced the highest levels of PD.
• Machines that were still fitted with their original windings, had lower levels of PO
than rewound machines.

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10.3 Final statement and recommendation

This paper proves that although 3,3 kV motors are not subjected to the same amount of
PO exposure than the higher voltage motors, the winding design as far as semiconductor
layers, stress relieving tapes and coil spacing is concerned, should be treated in the
same manner as the higher voltage machines.

The industry standard to neclect these protective measures on 3,3 kV motors should be
reconsidered.

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List of references

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4. Stone, G.C., Sedding, H.G. and Griffith, G. Experience with on-line Partial
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5. Sedding, H.G. Basics of Rotating Machine Partial Discharge Testing, Canadian

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9. McAllister, I.W. and Crichton, G.C. Partial Discharge Transients: The Field Theory
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14. Cabanas, M.F., Melero, M.C., Orcajo, G.A., Rodriquez, J.M.C. and Sariego, J.S.
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16. Stone, G.C. Techniques for On-line Partial Discharge testing of Motors and
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17. Tetreault, S. Experience with On-Line PD Testing on 4 kV Motors, Iris Rotating

Machine Conference, Dallas, Texas, March 1998.

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18. Stone, G.C., Campbell, S.R., Sedding, H.G. & Levine, J. A Continuous On-Line
Partial Discharge Monitor for Medium Voltage Motors, CEA Fourth Motor and
Generator PO Conference, Houston, TX, June 1996.

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