CORE REPAIR AND TEST

Its not so simple to answer, because its need depth experiences to repair this part,
however the damaged core as in the figure is still possible to repair.
Following step may can helping you to repair:
1. Remove the stator coil and surge ring support
2. Remove the compression bolts and finger plate from frame
3. Remove the damaged stator core (if need to replace)
4. Clean out by dry air
5. Cut the damaged stator teeth core
6. Grinding the damaged stator surface core, do careful and avoid the metal dust fill
in side
7. Clean up by using clean cloth and by dry air
8. Separated the damaged core lamination by using thin knife (round 1 mil thick)
9. Sprayed by insulation varnish onto separated lamination sheet
10. Dry out
11. Pull back the lamination onto its position
12. Applied the epoxy / resin or RTV onto these lamination
13. Repair all damaged finger plate or replaced
14. Re assy the compression bolt acc to the torque required.
15. Test the core looseness after compression bolts has been tighten, found loose on
the lamination is indicate loose on compression bolts
16. Test and analysis the core repair result with EL CID or Loop
17. Any unsatisfactory result must be repaired.
18. Clean up and spray paint coating
19. Core ready to refitting coils
Following is figures as references.

Compression bolts

The failure to tightened of core ay result in core damage, as well as damage to the
insulation of the core-compression bolts.
Following is a simple method of calculating the torque required on the core compression
bolts of many poles machine. If manufacturer data not available.
calculate the net area of core:
Net area [ in
2
] = 0.7854 x [ OD
2
ID
2
] [ No. of slot x width of slot x depth of
slot ]
All dimension in inches
Total Force in core [ lb ] = Net area [ in
2
] x 150 lb/in
2

150 lb / in
2
is a typical value, the specified value for machine can be obtained from
the manufacturer
Force / bolt [ lb ] = [ total force in core x OD/ID ] / [ No. of bolts ]
The required torque per bolt is:
T [ ft-lb ] = Force per bolt / bolt torque constant
The bolt torque constant is a number that depends on the type of bolt and bolt
size see ASTM Std A 193-B7
In 2-4 poles machine the compression bolts travel through the core lamination.
In this case the force per bolt is approximately equal to the total force in core
Total force per bolt Force in core [ lb ] = Net area [ in2] x 150 lb/in2
Ref : Inspection of Large Synchronous Machine. IEEE Power Engineering Series


INSPECTION AND TESTING
1. Core Looseness
Core looseness usually will occur at the inside diameter near the ends of the core.
However, it is possible for looseness to be general and/or exist on the core outside
diameter.
If looseness is suspected, degree of looseness can be evaluated by carefully inserting a
knife blade between punchings at several locations. If a 10-mil (1 mil = 0.0254 mm)
blade penetrates more than round a quarter of an inch (6mm), the core may be not
sufficiently tight.
EXTREAME CARE SHOULD BE TAKEN NOT TO BREAK THE BLADE, LEAVING A PIECE IN
THE LAMINATIONS !
Looseness may be accompanied by dust generation, punching and spacer movement, or
small pieces of punchings flaking or cracking off.
1. Digital ELCID
Electromagnetic Core Imperfection Detection (EL CID) is used to check the integrity of
inter-lamination insulation for stator cores of generators and motors. A fault current
occurring within the laminated stator core results in a hot spot and can cause a
catastrophic failure of a generator and motor

1. Loop Test
Loop is also to test the interlamination core, but its require high current power supply
and voltage (normally 220 380 V), its very dangerous, special attention for electrical
shock must be care.
Loop test is required Ampere Turn looping entire stator core,
Ilustration,

How many turns of cable is depend on the stator core dimensions, such as:
Core Outside diameter, core inside diameter, slot depth, core length. Following formulae
to determine of cable turn and cable dimension required.
T = (E x 10
5
) / (4.44 x f x Q
t
)
Q
t
= B
C
x Ac
e

B
c
= 8 x 10
4

Ac
e
= L
e
H
e

L
e
= .93 [L (n x wd)]
D
M
= ID + 2S + H
e

L
m
= x D
m

W
l
= 1.6 watt / lb
W
b
= Ac
e
x L
M
x 0.2764
AT = 12 x L
M

I
M
= AT / T
I
w
=( w
e
x w
b
)/ 50
Dia. cable = 500 x I
m
(circ.mills)
1 Mill = 1/ 1000 inch
L
e
: Effective L core
Ac
e
: Effective area of space duct
L
m
: Magnetic Length of core
Q
t
: Total Flux
B
c
: Flux Density
W
b
: Bore weight
H
e
: Slot height
ID : Inner diameter of core
AT : Amper turn
I
M
: magnetizing current
I
w
: Web current
n : no of space duct / air duct


Instruments and equipment / tools required:
1. Thermo vision
2. Cables
3. Regulator Power supply
4. Clamp ampmeter
5. Cable support
Standard req. taken from VDE 0530
PART OF MACHINE A E B F H
A.C. Winding of turbine type generator with rated output of 5000
kVA or more
60 70 80 100 125
A.C. Winding of salient pole and induction machine with rated out
put of 5000 kVA or more, or having core length of 1 M or more
60 70 80 100 125
If by way of an exception the embedded temperature detector
method be used on machines under 5000 kVA, the limit of
temperature rise given in this item shall apply
60 70 80 100 125
A.AC. Winding of machine with rated output smaller than in item 1.
Field winding of a.c. and d.c. machine with d.c. excitation exception
machine in items 3 and 4. Winding of armature of a.c. and d.c.
machine with commutator
60 75 80 100 125
Field winding of cylindrical rotor with d.c. excitation 65 80 90 110 125
Multi layer field winding of low resistance and compensating winding 60 75 80 100 125
Single layer winding with exposed bare surfaces 65 80 90 110 125
Permanently short-circuited insulated windings 60 75 80 100 125
Permanently short-circuited uninsolation windings

Iron core and other parts not in contact with the windings

Iron core and other parts in contact with the windings 4) 60 75 80 100 125
Commutator and Slipring, open or enclosed 5) 60 70 80 80 80
Journal bearing and rolling bearings 50 50 50 50 50
Rolling bearings using special grease 60 60 60 60 60
1). A correction is necessary for a.c. winding for rated voltage above 11 kV
2). The temperature rise of parts of machines rated at 5 MVA and above or having core
length of 1 M or more, which are insulated with class F or class H materials, shall not
exceed the limit of temperature rise for class B materials
3). Where the thermometer method is used, the limit of the temperature rise is that
given for the resistance methd less 10 deg.C in the case of classes A, E. B. 15 deg.C
with class F and 20 deg.C with class H materials
4). The limit of temperature rise is detrmined by the class of the insulating material of
the embedded winding
5). If no marked thermal interaction between the commutator, or the sliprings, and the
winding connected thereto is to expected, the limit of temperature rise applicable to
these parts are those assigned to their respective insulation classes
6). In the case of commutator and slipring the limit of temperature rise may be
exceeded by 10 degC with class F, and by 20 deg.C class H materials.
Core analysis by using loop test for big machine is very dificult, its require big power
supply, cables, too many man power. imperfection lamination underneath of core teeth
can not detected, ELCID is the best to analysis your stator core.
Pls be careful, and GOODLUCK......
Rgds
Siswanto
sis_cahya@yahoo.com
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