MECHANICAL INTEGRITY CHECKING OF GENERATOR STATOR

OVERHANG BY NATURAL FREQUENCY MEASUREMENT

R.K.Bhatnagar, A.K.Mukherjee,
National Thermal Power Corp., India
akmukherjee04@ntpceoc.co.in


INTRODUCTION
Reliable operation of generator is highly dependent on the electrical and mechanical integrity of stator
winding. Failure of generator stator conductor due to electrical or mechanical problems will lead to
long force outage of the unit resulting into huge revenue loss. As per our experience, most of the epoxy
mica insulated generator stator conductor failure occurs due to loss of mechanical integrity of either
overhang conductor or core looseness. This paper describes our experience of ensuring mechanical
integrity of epoxy mica insulated stator conductor at the overhang region.

DESCRIPTION
Singrauli Super Thermal power station is the first power station build by NTPC. It has installed
capacity of 2000MW comprising of 5X200MW units and 2X500MW units.
The Generators of 200MW units are designed by M/S Electrosila, Russia and manufactured by BHEL.
The stator winding of generators are directly cooled by de-mineralized water passing through hollow
conductors of the stator winding. Stator core and rotor are cooled by pressurized hydrogen gas. The
rating of the generator is 235MVA, 15.75KV, 0.85lag, 3-phase, double star connection and 3000rpm.

The generators are having 60 slots with 2 nos. stator windings per slot. Each stator winding conductor is
made of both hollow and solid conductors. DM water passes through hollow conductors for conductor
cooling. DM water pressure is maintained less than casing hydrogen pressure to prevent entry of water
into the generator in case of hollow conductor leakage. For detecting hydrogen gas leakage through
stator conductor, gas trap device has been provided.

The stator winding conductors are insulated by F class epoxy based mica insulation. Overhang
conductors of stator winding are supported on stator casing by fiber glass ring and fiber glass blocks.
Conductors at overhang are tied with the fiber glass ring by polyester cord. Near the exit point of the
conductor from core, one epoxy putty ring was made to reduce overhang conductor vibration. Top and
side ripple spring has been provided in the slot to further reduce conductor vibration.

OVERVIEW OF GENERATOR STATOR
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OBSERVATION

The unit-3 Generator of SSTPS was commissioned on 28
th
March 1983.
On 23/12/04 stator conductor leakage was observed in the generator. The important observations are as
given below:-

On 23/12/04 consumption of hydrogen increased to 6 cyl. in 24Hrs. from 3 cyl. Small micro
bubbles was observed to be coming out from the gas trap
On 29/12/04 drops of water was found seeping from expansion tank cover
Dissolved oxygen in stator water was 150ppb.
Stator water flushing carried out through gas trap and dissolved oxygen of stator water increased
to 700ppb.
On 30/12/04 stator water flushing was stopped and dissolved oxygen was again reduced to
150ppb.
Hydrogen was detected in expansion tank also (7%) after expansion tank vacuum was killed.
The appearance of hydrogen gas bubbles in gas trap and expansion tank along with increase of
hydrogen consumption indicates stator winding hollow conductor leakage.
The reduction of Dissolved Oxygen of stator water from normal value of 2100ppb to 150ppb also
supports the above analysis
Machine was shut down on 31/12/04 at 0757Hrs.
Leakage was detected in the connecting bar between 31 Top bar to C4 (B Ph.) bushing



























EE
TE
PH TE
1C1
2C1
NE
C4
40 39 38 37 36 35 34 33 32 31
4 5 3 2 1 60 59 58 57 56
3 2 1 4 5 6 7 8 9 10
27 26 28 29 30 31 32 33 34 35
TOP BAR
BOTTOM BAR
B PHASE
ELECTRICAL CONNECTIONS OF
STATOR WINDING
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Leaking bar
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After removing the insulation, crack was detected in the first bend of copper conductor
L shaped Aluminum support bracket just below the defective bar at
5 O clock position supporting phase connector 55B-C5 was found broken
Some blocks of supporting bracket at 11 O clock position was found loose
Black paste was found at the slot exit in top and bottom part of overhang
Paste like fretting product was found in the putty ring area and overhang support area


FAILED OVERHANG CONNECTING BAR
PASTE OBSERVED ON OVERHANG




Minor cracks were also observed in the overhang support brackets
After replacement of defective bends, machine was taken into service.







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SECOND FAILURE:-
Again in May-05, stator conductor leakage was detected.
Machine was shut down in J une-05.
Leakage was observed in first bend of 11 Top to C6 connecting bar.
In this occasion natural frequency testing of overhang conductor was carried out for the first time
At 4 places natural frequency was observed to be around 100HZ.
Strengthening of the overhang conductor was carried out to shift the natural frequency from
100HZ range.
Defective bend was replaced
Machine was taken into service and no problem was observed till date
The machine was re-inspected 2006 and no problem was observed.

ANALYSIS OF PROBLEM

To detect the root cause of repeated failure fractography analysis of the cracked surface of copper
conductor was carried out. The analysis indicates that the crack has developed due to fatigue. Fatigue has
developed due to repetitive loading caused by conductor vibration at the overhang region. No sign of
overheating or corrosion was observed. Failure of aluminum support bar also indicates presence of
vibration in the overhang region. The fractography analysis of the fracture surface of the aluminum
support indicates presence of beach mark caused by fatigue.
The above observation indicates presence of high overhang conductor vibration.
The presence of fretting product also indicates overhang conductor support looseness and subsequent
vibration of the overhang conductor.

During shut down of the machine in J une-05, natural frequency testing of overhang conductors revels
that at 4 places natural frequency was near 100HZ particularly at the places where failure has taken
place. The matching of natural frequency with core vibration frequency i.e. 100HZ resulted in excessive
conductor vibration due to resonance when the generator is in service. The presence of excessive
overhang conductor vibration has caused repeated failure of overhang conductor.

Overhang conductor of these types of generators are supported by fiberglass ring and blocks. Gaps
between fiberglass ring and overhang conductors are filled by glass webbing soaked in epoxy resin. But
when the support blocks are tightened, some micro gaps exist in tangential direction.

Secondly epoxy resin shrinks when it is cured. Due to this property of resin, micro gaps are formed
between conductors and its support after prolong operation.

So when machine is in operation, due to presence of micro gaps between conductor and support, the
support and conductor will not vibrate as a monolithic mass. This will cause further looseness of
conductor and subsequent increase of amplitude of vibration. Conductor vibration will become severe
when natural frequency of conductor approaches to 100HZ (core vibration frequency) and will result
into failure.





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CONCLUSION

Looseness of overhang conductor (where overhang conductor is supported by fiber glass blocks, rings
and tied by lacing) will occur after prolong operation of the machine. By measuring natural frequency of
overhang conductor during overhaul, this type of problem can be detected at a very early stage and
corrective action can be taken to avoid premature failure of stator winding conductor.

In NTPC we are carrying out measurement of natural frequency of epoxy mica insulated overhang
conductor (where overhang conductor is supported by fiber glass blocks, rings and tied by lacing) of
generators during generator overhaul and corrective actions were taken on the basis of natural frequency
of conductor.

Reference:
1. I. Culbert, et al. Handbook to Assess the Insulation Condition of Large Rotating Machines, EPRI
Power Plant Reference Series, Volume 16, 1989