21, rue dArtois, F-75008 PARIS

A1_204_2010

CIGRE 2010

http : //www.cigre.org

Experience with continuous monitoring partial discharge testing in a predictive

maintenance application of three similar hydro machines
A. Tabernero*, B. Batlle, O. Martnez, A. Villarubia, S. Rodriguez, E. Naharro
IBERDROLA & unitronics electric
SPAIN
electric@unitronics.es

SUMMARY
In present day, there are several reliable On-Line techniques helping to perform predictive
maintenance on large rotating machines. This work is related with one of these proven cost-saving
methods for stator insulation testing: On-line Partial Discharge.
The system under experience is an on-line Partial Discharge system that implements noise reduction
based on flight time. This is perhaps the technology that can best discriminate noise sources from real
machine partial discharge.
This system is part of a project from Iberdrola to improve the reliability of its power generation and
knowledge of their generator status in remote locations (hydraulic installations) or of great strategic
interest based on present/actual predictive maintenance practices.
In this work we present:

A look into Iberdrola generation capability & actual maintenance program.

A description of the machines object of the test:
A description of the physical implementation of an on-line PD testing system for the three
hydro units.
The investigation work performed along some months with On-Line PD.
Diagnosis experience of the data taken from the installation.
How this information is complemented with other off-line tests and maintenance history of the
machine to have the greater level of confidence with the machine operational.
Trending: the test is performed in a period of months, too low for PD trending. As PD
evolution is a slow process, it is not expected to get much information from trends. A future
second part of this paper in 2 years could help about this and from the evolution of PD works.
Gross evaluation about cost reduction and extra benefits from on-line PD implementation.

This paper will try to present an overview of the use of continuous monitoring On-Line partial
discharge as a predictive maintenance technique and to detect incipient problems in relevant power
generation machines. The benefits coming from the economic side and the advantage to have real time
information on machine stator insulation status.

andres@unitronics.es

Figure 1: Maintenance works of an Iberdrola hydro generator.

KEYWORDS
Partial Discharge On-line testing - Predictive Maintenance - Insulation testing - Stator insulation
Electrical insulation
1.- ABOUT IBERDROLA
Nowadays Iberdrola owns 41.001 MW of power installed in Spain, Latin-America and United
Kingdom (Scottish Power), corresponding to different generation technologies. In Spain, the 26.509
MW of power installed are distributed as:

Hydraulic:
Thermal Coal:
Thermal Gas-Fuel:
Nuclear:
Wind & Mini-Hydraulic:
Combined Cycle:
Co-generation:

8.842 MW
1.253 MW
2.889 MW
3.344 MW
4.977 MW
4.800 MW
404 MW

In terms of production centers it means:

One nuclear power plant owned 100% and different percentages in another 5 plants
3 coal fired power plants
4 fuel-oil & gas fired power plants
9 combined-cycle power plants
80 large and 93 small hydro-power plants
The first company in the world about wind-generation power installed with more than
3.800 MW

In terms of relevant machines it means:

29 Turbo generators from 148 to 514 MW, cooled by H2 and air

1 turbo of about 1.000MW water cooled

156 large Hydrogenerators, 33 of them with more than 100MW

In order to manage the predictive maintenance of these number of machines, Partial Discharge test has
been used from years in predictive maintenance policy. This test gives information about the general
state of the insulation and indicates if there are areas within the insulation with any special risk of
failure or potential degradation.
Iberdrola defines the following types of predictive inspections of rotating machines. They depend of
its aim and situation. There, On-Line PD & EDA are considered as the main routine test for all
rotating machines: Hydrogenerators, Turbogenerators and MV Motors.
Table I: Description of the Maintenance program of Iberdrola for Rotating Machines.
Basic or first level inspection inside of Maintenance program. Routine tests.
EDA
On-Line Partial Discharge
B Specific or second level inspection inside of Maintenance program. Special or type tests.
Generators Rotor Windings
Internal Visual Inspection
Stator Windings
Insulation Resistance and
Power Factor
Polarization Index
Off-Line Partial Discharge
Winding Resistance
Winding Resistance
Impedance
Surge Test (If multiturn coils)
Surge Test
RSO
After repair (cleaning or rewinding) or first test on new machines / intensive inspection when
the rotor is disassembled. Intensive Tests. These inspections on regular bases are only performed
C
in Generators. In motors, these kinds of tests are only carried out during repair or fault
investigation.
Stator Windings
Core tests
TVA Test.
EL CID
Wedge Tap Test.
A

The periodic bases of these inspections will depend of machine characteristics, running hours,
operation characteristics, machine importance for operation, machine status, if there is redundancy,
etc. Anyway, as a general basis, following periodicity is established for Turbo generators, Large
Hydro and MV motors, in years:
Table II: Periodicity of Maintenance Works per rotating machine in Iberdrola facilities.

MACHINE
INSPECTION
<20
Age
2040
(years)
>40

A
2
1
1

TURBO
B
2
1
1

C
6
5
5

YEARS
HYDRO
A
B
2
4
1
3
1
2

C
12
9
6

MOTOR
A
B
2
10
1
5

As you can appreciate, in order to reduce assembling and disassembling works and time consumption,
as well as have bigger information as possible in each inspection, type A is always performed at the
same time that B and A+B when inspection type C is carried out.

2.- MACHINE DESCRIPTION

The objects of this study are three identical pumps generators. They are part of a remote location
power plant from Iberdrola that performs a very fast response to the needs of the Spanish grid. REE
(Spanish regulator for the distribution grid) ask for power from the plant generators and in other
moments, when there is excess of power generated in the grid, the machines act as pumps elevating
water to an upper reservoir. These machines are so useful to Iberdrola that it is being built an
expansion of another four machines working with the same water reservoir. The capacity will change
from 555MW to 1110MW pumping and from 630MW to 1260MW in generation. This will between
the bigger European pure pumping plants in Europe.

Figure 2: Water reservoir for the storage pump generators. Actual machines get water from the
conduct seen and new machines will get it from inside the mountain.

There are three identical Hydro-generators, named from now as G1, G2 & G3. These
machines were manufactured from CADEMESA (BBC Brown Bovery licensed) with main
characteristics:
Age

Voltage

Power

Frequency.

1989

14,5kV

230MW

50Hz

Power
Factor
PF=0,9

Speed

Insulation

500/700rpm

Class F epoxy-mica

3.- PHYSICAL IMPLEMENTATION OF THE PARTIAL DISCHARGE SYSTEM.

Each generator is made up from three parallels each phase. Each phase has three couplers to get the
most amount of information from the machine. The machine has a total of 9 couplers that were
installed in the last two years.

Figure 3: Example of G1 DAU (Data Acquisition Unit). It receives all the couplers, generator
operating signals and performs continuous on-line measurement.
All nine couplers go through coaxial cables to a passive Terminal Box. Attached at each terminal box
is connected a DAU (Digital Acquisition Unit) that performs the PD acquisition. All three groups
connect to a control computer that guides data acquisition. Next table shows the position of each
coupler and the slots covered by each one.
Coupler
1
2
3

U slot (coverage)
051 (022 to 081)
111 (082 to 141)
171 (142 to 180,
001 to 021)

V slot (coverage)
061 (032 to 091)
121 (092 to 151)
001 (152 to 180,
001 to 031)

W slot (coverage)
071 (042 to 101)
131 (102 to 161)
011 (162 to 180,
001 to 041)

Figure 4: Local Control Room. The installation will be remote controlled but in this room there
is a PC to perform supervision and local control of all units.
Unitronics electric (Spanish distributor of Iris Power) installed with Tresa the system while 2009.
Characteristics of the installed PD system:

3 DAU (Data acquisition units), manufacturer Iris Power, model PdGuardPro one for
each group G1, G2 & G3.
9 x 80pF capacitive input sensors per machine.

Each DAU has:

3 current loop to relate PD acquisition with kV, MW and MVar of the machine
2 current loops to relate PD with moisture and temperature of the machine.
Communication via Ethernet to the Control Room.
Control computer connects to each DAU via a switch and to the external world with
another link (already not installed) to allow remote control of the system.
Control Software (PdGuardPro) has the main functions:
Discriminate noise, classify PDs with level, pps & phase.
Classify PD in 2D, 3D correlated with the main parameters that change PD in
hydraulic units (kV, MW, MVar, C & moisture).
Perform triggered Data acquisition with pre-programmed special conditions to have
trendable results with time. Manual measurements are also allowed.
Supports working with alarms defined from the user on determined PD levels.
Analysis software (PDView) has functionality to look to PD from different points of
view, 2D, 3D, trends and allow a powerful data manipulation / reports, etc.

Figure 5. DAU in Group 3.

4.- INVESTIGATION WORK
Here we present the results of all the tests performed in these generators around predictive
maintenance. Both Off-Line and On-Line tests are presented. Rotor was also examined but it is not
presented here. First, we present all the techniques used and after the tests performed together with a
preliminary analysis previous to the final diagnosis. The parameters presented are from the tests
performed after the cleaning works.

Internal Visual Inspection. Taking advantage of machine programmed stops, all units
were inspected. Rotor were extracted and stator was subject to a deep check performed
by expert personnel. This is the best tool to detect the effects of the different degradation
mechanisms, especially if those happen in the end-winding area.
In general, after works of cleaning and repairs, all machines had a final satisfactory
status. All machines had initial traces of contamination of dust / oil coming from
mechanical brakes that were successfully cleaned. Windings were ok, no symptoms of
abrasion or big clues of PD, no surface currents. Endwinding ties were well and with
good mechanical rigidity. Core was in good status, and with good core pressure. In
particular machines had these problems now solved:
G1= Slot 5 had all wedges displaced down. Detected possible PD or rubbing evidence in
endwinding of slot 175. Punctual crack in inferior endwinding of bar 134.

G2= In slots 40-60 oil spilled while dismount. Machine was cleaned and dried twice.
G3= 3 punctual locations in endwindings were repaired

Insulation Resistance & Polarization index. Values are extracted from EDAIII test.
Test voltage 2500V. Values corrected at 20C.

IR & IP for Generator Phase U/ V+W+GND

@20C
(G)
IR
PI
G1
3,599
6,71
G2
3,357
4,84
G3
1,479
6,67

Phase
V/
U+W+GND (G)
IR
PI
3,862
6,76
3,132
4,85
2,540
6,38

IR & IP for Generator @20C

All Phases to GND (G)

IR
PI
1,100
3,37
1,192
3,60
1,274
3,54

G1
G2
G3

Power factor or Dissipation factor (tan ) and tip-up. Tan delta gives a global
indication of losses in the dielectric and can give a clue of the thermal aging status of the
machine. Test is performed in five steps from 0,2Un/3 to Un/3.

tan @ 0,2Un/3 y Phase U

Tip up tan
Tan
G1
1,37
G2
0,89
G3
1,12

Winding
@75C
G1
G2
G3

Tip-up
0,09
0,14
0,12

Phase V
Tan
1,36
0,82
1,11

Tip-up
0,12
0,13
0,14

Phase W
Tan
1,45
0,81
1,11

Tip-up
0,06
0,17
0,15

Capacitance and capacitance tip-up. High voltage capacitance deduced from tan test
also gives clear indication of changes in the insulation system. It monitors moisture and
other abnormal conditions. The tip-up indicates how changes the equivalent capacitance
with voltage, this says us how changes the amount of PD (Partial Discharges) voids
activated by voltage increase. It also monitors moisture ingress and delamination.

Cap.
@ Phase U
0,2Un/3 y Tip
up Cap.
Cap. (pF)
G1
82540
G2
82368
G3
82008

Phase W/ U+V+GND
(G)
IR
PI
3,619
6,52
1,632
4,83
2,182
6,66

Phase V
Tip-up
0,73
0,53
0,46

Cap. (pF)
82090
82429
81964

Phase W
Tip-up
0,91
0,42
0,46

Cap. (pF)
82440
82485
81799

Tip-up
0,75
0,50
0,53

Winding Resistance. Star of the generator is open. Winding is measured with four-wire
method. Values are corrected at 75C.
resistance Phase U-X (m)
1,404
1,435
1,379

Phase V-Y (m)

Phase W-Z (m)

1,405
1,423
1,385

1,404
1,411
1,389

Off-line Partial discharge analysis. This test may be performed together with TVA
test. Units are energized one phase at a time and PD is recorded.

TVA probe. TVA Probe testing (Tennessee Valley Authority Probe) allows physical
location of the partial discharge activity, mainly if it is a slot discharge problem. Test
was performed at 7,5kV taking readings in slots, endwinding and rings.
G1& G3= Readings low (below 7mA).
G2= Readings low but in two areas: slots 40-60, U & W (up to 35mA) and 140-150 (W
up to 12mA).

WTD. Wedge Tap Test. This test checks the proper working status of all wedges that
support the bars into slots. There are 180 slots and 16 wedges each slot. Sampling is only
performed in a total of 4quarters*10 slots*16wedges=640points instead of
180*16=2880points. After repairs in group G1, slot 5, all results for G1,G2 & G3 were
good.

EL-CID. This is a low power core test to check the insulation between layers of the
laminations. The core is made up of 180 slots of 2,3m, 2 conductors each slot, 60 turns
each phase, 3 parallels each phase. Test was performed only each 10 slots. Results for
groups G1, G2 & G3 good <100mA for quadrature signal, phase and quadrature signals
with good ratio between them.

5.- DIAGNOSIS
Windings: From winding resistance & Visual inspection, all three machines dont show problems of
phase imbalance due to poor connections or bad welding.
Core: From the samples taken from EL CID test and visual inspection, the core seems to be in a good
status without signs of hot spots.
Bars support: From the results of WTD it indicates that windings are tight in the slots, they do not
vibrate and semiconductor & insulation layers wont result damaged.
Insulation is the element that supports the life of the windings and so of the machine, so its status is
deeply diagnosed from three points of view:
Insulation from off-line DC test point of view: From IR, IP and EDAIII tests.
G1: Good results for the age of the machine.
G2: Test performed after cleaning didnt show expected improvements, possibly due to moisture in
the insulation that is expected to improve after some work of the machine.
G3 test performed indicate improvements in insulation after cleaning works. Machine parameters
show good for the age of the machine.
Insulation from off-line AC point of view: From tg , TVA, & Off line PD tests.
G1: Good results for the age of the machine.
G2: Tan delta gives good score. TVA problems in slots 40-60 in phases U & W due to oil spilled.
Minor activity in slots 140-150W, low possibly due to voids to ground or defects in semiconductor
layer.
G3: Tan delta show good result without big losses, delamination or DP signs. TVA low activity. Offline DP show a small DP accumulation in phase C at 0 & 180 with some positive predominance.
Could classify as a minor connection problem not correlated with winding resistance.

Insulation from on-line AC point of view: On line PD tests. When machines are installed in the field,
PD is many times confused with another noise signals. Remember: when we measure machine PD, we
do only ask for PD coming from the stator insulation, but there is also noise in the bus, conducted
noise, interference
It is important son, to take apart noise from PD, as IEEE 1434 says with time of flight noise extraction
systems. Using this today available techniques, diagnosis is easier.
An example of a procedure to evaluate a machine using PD could be the next:

1)
2)
3)
4)
5)
6)
7)
8)
9)
10)

Register PD with noise extraction. Better if PD can be recorded at different conditions of

load / temperature.
Extract 2D & 3D PD information.
Extract numeric data: NQN+, NQN-, Qm+& Qm- of each phase & coupler.
Compare results with Iris database from similar machines in the world.
Compare data between similar machines in the install.
Compare data between phases.
Compare PD+ with PD- in 2D.
Compare 3D.
Evaluate remaining noise.
Compare measurements with previous ones if available (trending).
Extract PD location sites in the stator.
Deduce PD location inside the insulation.
Give conclusions based in PD interpretation and emit recommendations. If necessary
change according maintenance program dates.

From the next table and the interpretation of 2D & 3D plots we should give the final diagnosis.
G1 (mV)
G2 (mV)
G3(mV)
Qm+
QmQm+
QmQm+
QmA1
000
000
000
000
000
000
A2
259
288
000
000
000
000
A3
098
099
175
172
000
000
B1
000
000
403
143
082
090
B2
188
000
383
000
Broken
Broken
B3
000
075
000
000
No sync
No sync
C1
000
000
109
269
166
175
C2
093
084
473
397
000
000
C3
000
000
183
149
060
042
Test #
179184 (unitronics)
761766(unitronics)
04/2009 (iris power)
Problematic areas are highlighted in red, high in brown, moderate in blue, rest in green. Iris database
(IRMC 2008) states for this kind of machines (air cooled differential PDA) the risk Moderate (7590%) up to 371mV, High (90-95%) up to 551mV and Problems above 551mV.
G1: Moderate levels.
Phase A2 to B2. Suggests phase / phase discharge, likely in the endwinding.
G2: Some High levels.
Phase B2= Slow increased (+) activity up to High level, maybe due to semiconductor layer
degradation.
Phase C2= Voids in the insulation of phase C to ground. Just watch its evolution.
G3: Medium activity.
Phase B2= Coupler not working.
Phase C1= Voids inside insulation due to normal insulation degradation.

From all tests performed and after a preliminary analysis of them, the diagnosis and recommendations
to the machines are given here.
G1 = Check PD On-Line evolution & perform analysis with temperature & load variations. In next
programmed inspection review endwinding (most slot 134).
G2 = Check PD On-Line evolution. If increase continues program visual inspection, TVA, tg , PD
off-line tests.
G3 = Check PD On-Line. Machine is ok. Revert sync to B3. In next inspection review coupler B2.

6.- ECONOMIC VALUATION

Nobody can deny today the benefits of inversions in maintenance. Even better are the goods of
Condition based maintenance and the future leads us to on-line systems. Apart from the usual
vibration measurement systems that detect a great part of possible faults before they should appear,
today, we have available On-Line Partial Discharge detection systems. Most of the savings will be
related to the unavailability of the system, works to connect & disconnect the machine, human work,
etc. In the next table we can see a resume of different situations that could happen in a machine and a
gross economic valuation on this.
What Happens?
Measurements
say OK

With on-line PD
Only off-line tests
We are sure that insulation system Insulation general status tested off-line
general & punctual of the machine is only between maintenance revisions.
good and stator is ok
Measurements
Just clean / minor repair. Decide to Machine under damage till damage
say mild failure
test immediate or next revision.
detected (could be unnoticed if only tg )
Clean=35.000
Urgent clean=50.000
Stop time=1 week, 4 people
Stop time=2 weeks, 4 people
Measurements
Minor repair, for example repair of 1 Great fault complete rewind.
say
serious bar.
failure
Work=900
Cost=1.500.000
Stop time=1 week, 4 people
Stop time=40-42 weeks, 11 people
Numbers obtained from a prestige service Spanish workshop. If doubt, make your own similar
numbers and compare.

7.- CONCLUSIONS
When machines are aged: this is around 30 years of insulation life, it is important to have a deeper
knowledge of the status of the insulation. With on-line PD and regular off-line testing, the life of the
machine can be extended some 20 years more just with some low price works. Other times, machine
power could be reduced if latent problems are detected trying to limit the accelerated aging of the
machine in service.
What are the advantages of on-line PD testing?. When a problem is detected it gives an effective
saving of cost to the utility and if everything goes well, the responsible of the machine can definitively
trust in the machine and hast the best tools to assess its security. The final intention of predictive
maintenance is to increase profits. Why? If you give better service and product to the customers you
are in a best position to competitors.

10

Next: When this system is remote controlled, it will be implemented programmed alarms on the base
PD data expected. A revision of the PD results will be programmed each month and a PD trending is
intended to give a better knowledge of insulation status evolution.
We plan to update this report each 2 year of work to check the evolution of the machines.
At last we wish to thank people in the plant for their help and support.

8.- BIBLIOGRAPHY
Next are given different references most around partial discharge of interest, Hydro machines and
about related international normative.
[1] IEEE Guide for Diagnostic Field Testing of Electric Power Apparatus-Electrical
Machinery. IEEE Std. 62.2-2000.
[2] IEEE Guide for Operation and Maintenance of Hydro-Generators. IEEE Std. 4921999.
[3] IEEE Guide: Test Procedures for Synchronous Machines. IEEE Std. 115-1995.
[4] IEEE Guide for Insulation Maintenance of Large Alternating-Current Rotating
Machinery (10 000 kVA and Larger). IEEE Std. 56-1997.
[5] IEC60034-27. Rotating electrical machines Part 27: Off-line partial discharge
measurements on the stator winding insulation of rotating electrical machines.
[6] IEEE1434-2000 IEEE Trial-Use Guide to the Measurement of Partial Discharges in
Rotating Machinery.
[7] A. Tabernero and B. Batlle. Predictive Maintenance in Hydrogenerators. Hydro 2007.
Granada, Spain, October 2007.
[8] Claude Hudon, Mario Blec & Melanie Lvesque. Study of Slot Partial Discharges in Aircooled Generators. IEEE Transactions on Dielectrics and Electrical Insulation. Vol. 15, No.
6; December 2008.
[9] Shunyuan Li and Jennifer M.Y.Chow. Partial Discharge Measurements on Hydro Generator
Stator Windings Case Studies. IEEE Electrical Insulation Magazine. May/June 2007, Vol.
23, No.3
[10]
G.C.Stone, C.V. Maughan, D. Nelson, R.P. Schultz. Impact of Slot Discharges and
Vibration Sparking on Stator Winding Life in Large Generators. IEEE Electrical Insulation
Magazine. September/October 2008. Vol.24, No.5
[11]
Isidor Kerszenbaum. Inspection of Large Synchronous Machines. Checklists, Failure
Identification, and Troubleshooting. IEEE Power Engineering Series. 1996.
[12]
Greg C. Stone. Edward A. Boulter, Ian Culbert, Hussein Dhirani. Electrical
Insulation for Rotating Machines. Design, evaluation, aging, testing and repair. IEEE Press.
Wiley-Interscience. 2004.

11