Digital Front Ends Offer New Life for Aging Static Exciter Systems on

Hydro Turbine Generators

Gene Asbury, Senior Application Specialist, Basler Electric Company, Highland, IL USA

Abstract
Many static excitation systems were installed from the early 1980s and into the 1990s
to replace the aging rotating exciters for hydro generating plants in North America.
The Westinghouse MGR and the General Electric Potential Busfed systems were two of
the more common analog static exciter systems for field current ratings up to 1000Adc.
Today, even some of newer installed and early digital exciters are approaching 25 years
of age. Some parts may be available now, but with the passing of time, the chance will
increase that the control components of the older excitation systems will no longer be
available due to obsolescence.
The logical upgrade for the excitation system is to replace the entire system with a new
AVR/Static excitation system. Since the proposal costs may be outside budget
limitations and many power stage components still could be in excellent shape, it may
be beneficial to consider an alternative upgrade for the excitation systems.
This paper will discuss the application and advantages of retrofitting the excitation
system to replace the analog front end controls with a state-of-the-art digital controller,
firing circuits, power supplies, field ground detector, and other components ( depending
on the application), while maintaining the original excitation power bridge and Power
Potential Transformer. The advantages of this approach are lower cost, less complexity,
an integrated power system stabilizer (if required), and software tools that decrease
commissioning time, power system stabilizer tuning and NERC testing.
Introduction
In the 1980s and 1990s, it was common for many power plants, including hydroelectric,
steam, and combustion plants, to replace their dc rotating exciters with analog static
exciters. There are many reasons plant owners invested in static exciter system
upgrades. Several major reasons are listed below.
1.
2.
3.
4.

Reduces mechanical issues such as commutator and field breaker wear

Provides improved transient response
Reduces vibration issues
Reduces parts obsolescence issues for the electromechanical voltage regulator
and associated devices
5. Increases the efficiency of the system [1]
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Static exciters came in different styles, but the main difference was the power stage.
Some had six-SCR power bridges and others had three-SCR/diode power bridges with
no negative forcing.
The Westinghouse MGR (Medium Generator Regulator), shown in Figure 1, was widely
used at hydroelectric plants in North America on turbine generators of various sizes.
The MGR may be used as a voltage regulator by working into the field of a rotating
exciter or as static exciter working in to the generator field. An MGR controls a thyristor
bridge ranging from 20 Adc to 1,000 Adc. If more field current was needed, parallel
bridges were provided with the use of reactors for current sharing.

Figure 1 - Westinghouse MGR

Hybrid systems included the GE Bus Fed (Figure 2) and Basler SSE (Figure 3).

Figure 2 - GE Bus Fed Controller

(SSE)

Figure 3 - Basler Static Shunt Exciter

The Analog Exciter

There are many manufacturers analog excitation systems at hydroelectric plants in
North America, including OEM excitation systems. In most of these systems, the analog
control section may be upgraded to a state-of-the-art digital system while maintaining
the power control section. Today, first generation digital excitation systems are being
upgraded because of parts obsolescence and support issues. This section focuses on
upgrading the Westinghouse MGR, but a good portion can be used for upgrading other
manufacturers models as well.
The Westinghouse MGR simplex unit is illustrated in Figure 4. There are two cubicles:
the left side is the Power Cubicle and the right side is the Logic Cubicle. Each cubicle is
divided into separate panels. The following is a brief description of each panel.
Power Cubicle
DC Panel - This panel houses the field flashing circuits, the field surge
protection, and the shaft voltage protection. The 125 Vdc control power is
brought to this panel.

AC Panel - The ac field disconnect is the main component of the ac panel.

Also included in this panel are the ac surge protection, associated control
relays, and the control power transformer.
Power Converter Panel - This panel contains the power bridge and the
associated firing circuits, including fuses, snubber circuits, and pulse
transformers. Depending on the application and the size of the generator,
the bridge could be a semi-converting bridge or a full-converting bridge.
Logic Cubicle
Electronic Adjuster Panel - Electronic adjusters are mounted at the top
of the Logic Cubicle. With all options, the MGR system has three
adjusters; one for automatic control, one for manual control, and one for
var/power factor control.
Logic Circuit Panel - The logic circuit panel houses the main printed
circuit card modules, relays, and internal logic power supply. The three
modules on this panel are the voltage regulation circuits, limiter circuits,
and the protection circuits.
Voltage Regulation Circuits - Voltage regulation circuits include
the basic voltage regulator and reactive current compensation
circuit. If specified, this board also includes a var/power factor
regulation circuit.
Limiter Circuits - This circuit contains the maximum excitation
limiter, minimum excitation limiter, instantaneous current limiter,
and volts/hertz limiter. Independent auxiliary signals are provided to
move the excitation into the operating capabilities of the generator.
Protection Circuits - This is an optional circuit that provides
overexcitation protection, volts/hertz protection, and loss of field
protection.
Field Ground Detector - The field ground detector, when required,
provides protection against field ground faults. [2]

Figure 4 - Internal Components of an MGR Exciter

The Conversion to Digital
There are several factors, listed below, that tend to initiate an upgrade of aging analog
excitation systems to new digital excitation systems.
1. Parts availability and obsolescence
2. Model no longer supported by the manufacturer
3. Data recording and software tools needed for periodic response testing per
requirements by NERC
A complete replacement of an analog static excitation system can be expensive; thus,
reviewing all the options is necessary. If the power plant owner has determined that an
upgrade is needed but budget restraints do not allow the necessary funding, a front end
solution may be the only way to obtain the proper upgrade. Before a front end solution
is proposed, the following questions should be answered.
Question: Is the existing bridge in good shape? See Figure 5.
An inspection of the bridge is required to be sure it is in good working condition.

Figure 5 - MGR Rectifier Bridge

Question: What is the manufacturers part number for the SCRs used in the
rectifier bridge?
This information is needed to determine the required gate voltage (Vgt) and gate
current (Igt) to ensure correct firing by the new firing circuit and gate amplifier
circuit.
Question: What type of bridge is in the static exciter (full-converting or semiconverting)? Is a full-converting bridge required?
Although not required by regulations, the system operator may require a negative
forcing system to improve the transient response of the system.
Question: What are the existing Power Potential Transformer (PPT)
parameters?
This information is needed to ensure that the PPT is adequate for the application
and meets any new requirements applicable to the North American Electric
Reliability Corporation (NERC) region in which the machine is located (e.g.
increased ceiling levels). See Figure 6 for an example of a PPT nameplate and
the information needed.
6

Primary
Voltage

Secondary
Voltage

kVA Rating

Figure 6 - Example of a Power Potential Transformer Nameplate

Question: Is there enough space in the existing cabinet to house the new front
end panels?
This is not an issue with analog static exciters, but with first generation digital
exciters, there could be an issue. An inspection and measurements of the
existing cubicle are required.
Question: Can the field flash circuitry and ac disconnect be reused?
These are components that can be replaced with the new front end upgrade.
This is dictated by the equipment owner. An inspection of the components is
necessary.
After it is determined that a front end conversion is applicable, the design team
engineers the required panels based on the necessary equipment and options. Figure 7
shows a three-panel system that comprises a front end solution for an existing analog
exciter. The left panel houses the main controller, bridge control circuit, isolation
transducer, I/O circuits, and other associated components. The panel in the middle
houses more I/O circuits, power supplies, control relays, and other associated
components. The right panel is only needed when replacing a field ground detection
relay (64F). Another panel, not shown in Figure 7, may be used to house additional
bridge control circuitry, if the analog exciter utilizes multiple bridges.

Figure 7 - Digital Front End Panels to Replace Analog Circuitry on an

Analog Exciter
On simplex MGR static exciters, these three panels replace the electronic adjuster
panel, the logic circuit panel, and the field ground detector panel. Also, the firing circuit
and the gate amplifier circuits can be removed from the power cubicle.
The process of designing and manufacturing a front end excitation kit is identical to the
process of designing and manufacturing a complete excitation system. The following list
outlines the basic steps taken from the time a front end excitation kit order is received to
the completion of testing.

1. Purchase order is placed and engineering specification is developed.

2. Engineering approval drawings are developed and submitted to the
owner/customer.
3. After the owner/customer has approved the drawing, the final engineering work is
completed and the project is released to manufacturing.
4. The modules and circuit boards are individually tested before assembly on the
panels.
5. Once the panels are assembled, they are sent to the test cell. They are wired
together and connected to an external bridge. A complete functional test is
performed on the system.
6. If required, the owner/customer visits the manufacturers factory to witness-test
the front end excitation kit.

Figure 8 illustrates the front end excitation kit in the existing cubicle of the original
exciter. The three panels easily fit inside the existing cubicle. A 12-inch HMI touch
screen is installed on the front door of the cubicle. See Figure 9.

Figure 8 - Analog Exciter Converted into a

Digital Exciter

Figure 9 - HMI Touch Screen Display

Advantages and Features of a Digital Exciter

Digital excitation systems eliminate concerns associated with aging analog excitation
systems. A new digital exciter provides many added features, several of which are listed
below.

Better regulation accuracy (up to 0.1% from no load to full load)

Multiple pre-position set points for each mode of operation (initiated by userdefined logic)
Reactive differential compensation (cross current) via communication link
Field Voltage Regulation (FVR) operation mode is a manual control mode
designed to perform specific tests to validate models for load rejection and
capture generator
reactance. [3]

NERC VAR-002-1a and Associated Protection

A digital excitation system allows the user to more easily meet new requirements set
forth by NERC. One such requirement is described in standard VAR-002-1a, below.
The Generator Operator shall operate each generator connected to the
interconnected transmission system in the automatic voltage control mode
(automatic voltage regulator in service and controlling voltage) unless the
Generator Operator has notified the Transmission Operator. [4]
High end digital systems incorporate a feature that is common in the protective relay
world called 60FL or Voltage Balance Fuse Loss, see Figure 10. When an excitation
system loses a leg of its voltage sensing circuit, the exciter attempts to turn full on. Most
digital exciters monitor the balance of the sensing circuit and initiate a transfer to Field
Current Regulation (FCR or Manual mode) if an unbalance is detected beyond the
settable range. A severe transient on the grid can emulate a loss of sensing condition
and initiate a transfer to FCR mode. This transfer mandates a call to the system
operator within 30 minutes, based on the requirements of VAR-002-1a. To avoid these
nuisance transfers, the 60FL element monitors the positive sequence and negative
sequence voltage and currents, and the modern digital AVR controller determines if the
event is a true loss of sensing condition or a transient on the system. This feature allows
a transfer to manual mode only when there is a true loss of sensing condition.

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Figure 10 - Voltage Balance - Fuse Loss (60FL) [5]

Other protection elements that are commonly offered in a digital excitation system are:

Field Overcurrent
Field Overvoltage
Field Ground Protection
Field Temperature Protection
Generator Overvoltage
Generator Undervoltage
Loss of Excitation
Volts per Hertz Protection
Exciter Diode Protection (brushless exciter applications)

The protection elements can be displayed as an alarm or enabled as an output. The

output arrangement is set by programmable logic software. [3].
Power System Stabilizer
Depending on which NERC region the generator is located in or as a directive from the
Transmission Operator, a PSS may be required. In most applications, a PSS2B style,
integral of accelerating power, is required in North America. Figure 11 represents the
model for type PSS2B dual input PSS.

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Figure 11 - Type PSS2B Dual Input PSS [6]

If a PSS is required, this feature is integrated into the main controller of the digital
exciter. When a PSS is utilized, the excitation system is tuned to be very aggressive in
response to terminal voltage deviation to improve the transient stability of the system for
the first rotor swing. As the transient stability is enhanced, the natural damping in the
system is restored by the PSS [7]. Another valuable feature of the digital exciter is a set
of primary and secondary gain settings. These settings allow the user to tune the exciter
to be very aggressive when the PSS is active and slow the response when the PSS is
inactive.
To assist in the commissioning of the PSS, most modern digital controllers software is
equipped with the ability to perform the frequency response test with immediate bode
plot results. See Figure 12.

Figure 12 - Frequency Response Using a Built-in Dynamic Analyzer [7]

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Limiters
Analog excitation systems have several maximum and minimum limiters along with
instantaneous and volts/Hz limiters. Limiters used in modern digital excitation controllers
are listed below.

Minimum Excitation Limiter - This function operates in the same manner as

traditional analog systems in that the limiter curve is based upon assuming it is a
steady-state stability limit.
Underexcitation Limiter - The underexcitation limiter is identical to the
minimum excitation limiter. However, it can recalibrate the limit curve based on
hydrogen gas pressure or stator temperature.
Overexcitation Limiter An overexcitation limiter limits the duration of
excessive field current applied to the machines field.
Volts per Hertz Limiter This function limits excessive volts per hertz operating
conditions that could over flux the generator and connected transformers.
Overvoltage Limiter The overvoltage limiter protects the generator from
sustained, high levels of terminal voltage. This can occur during full load
rejection on hydro units.
Undervoltage Limiter An undervoltage limiter prevents the generator voltage
from reaching an undervoltage condition. Low terminal voltage can occur with a
failure of the excitation system.
Minimum Field Excitation Limiter - Where the minimum excitation limiter and
underexcitation limiter sense reactive power on the generator, the minimum field
excitation limiter monitors the field current and maintains it at a user-adjustable
level.
Instantaneous Overcurrent Limiter This limiter is similar to the overexcitation
limiter, but with no intentional time delay.
Var Limiter A var limiter prevents a high level of lagging vars that can be the
result of a failure within the excitation system.
Stator Current Limiter This function monitors the level of stator current and
limits it to prevent stator overheating. It only affects the reactive portion of the
generator line current.
Soft Start Soft start limits the rate at which the generator terminal voltage
builds towards the set point to prevent overshoot.

It is easy to see that modern digital excitation systems provide more flexibility and
control when regulating hydro turbine generators.
With the advanced software tools for modern digital exciters, setting the limiters and
coordinating them with protection becomes a more precise exercise. See Figure 13.
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This feature is now more valuable since the implementation of NERC Standard PRC019-1. The purpose of this standard is to verify coordination of generating units or
synchronous condensers voltage regulation controls, limiting functions, equipment
capabilities, and protection system settings [8].

Figure 13 - Underexcitation Limiter Programmable Feature

Auto Tuning
With the requirement to run the generator in AVR control, it is important to have an
optimally-tuned AVR system. Because most modern digital controllers utilize the
proportional, integral, and derivative (PID) control for stabilization, knowing all the
machine parameters (field time constants) is critical to properly tune the excitation
system. Not having this information causes a considerable time delay and higher cost
due to increased fuel usage for commissioning the AVR system [9] [10].
Modern digital controllers are equipped with an auto tuning feature that allows the user
to perform a test via the controller software (Figure 14) at rated speed and with the
generator breaker open.

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A - PID Design Mode: Set to either Pole Zero Cancellation or Pole Placement.
B - Power Input Mode: Set to either PMG External or Shunt.
C - Start Auto Tune Button: Begins the auto tuning process.
D - Save PID Gains Button: Saves the calculated PID gains.

Figure 14- Auto Tuning Initiation Screen

When the test is complete, the AVR system is tuned. Fine tuning can be performed
during the required step test. The Auto Tuning feature saves valuable time when
commissioning the excitation system.
Software Tools

Two software tools have been discussed in this publication thus far. The first one
provides the ability to perform a frequency response test while commissioning the PSS.
The other software tool is the auto tuning feature, which allows the user to quickly
obtain gain settings and time constant values. Another very valuable software tool is
Real Time Monitoring, see Figure 15. It allows the user or the Commissioning Engineer
to monitor up to six (6) parameters while doing a step response test. This saves time
during the commissioning process and for periodic NERC testing.

15

Figure 15 - Six-Channel Real Time Monitoring

The digital front end solution provides diagnostic tools that assist in troubleshooting.
These diagnostic tools include event recording, sequence of events reports, and, in
some cases, a trending report that provides an extended look at the generating units
performance.

16

The event recording tool stores multiple events in memory. An event can be triggered
by logic, a parameter exceeding a certain level, or a step response test. Figure 16
shows an example of an event recording that samples data in as fast as 1 millisecond.
This data can be viewed using the viewer associated with the interface software
package, a Comtrade format viewer, or using ASCII log data to generate the response
in a spreadsheet.

Figure 16 - Single Event Recording

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Sequence of events data is a powerful troubleshooting tool. It provides the user with a
detailed description of how the exciter has performed. It records every action the exciter
executes and records it with a time and date stamp. Time may be synchronized via an
IRIG-B input or through Network Time Protocol (NTP). The Sequence of events data is
downloaded in tabular format and is illustrated in Figure 17.

Figure 17 - Sequence of Events

Conclusion
There are many analog static exciters at hydro facilities all over the world. To meet
agency specific requirements or to prolong the existing excitation system, a front end
digital excitation kit may be the best solution. It provides many features that help the
user perform required periodic testing. A new digital front end also provides the tools to
troubleshoot the system when needed.
This publication focuses mainly on Westinghouse MGR exciters and how to retrofit them
with a digital front end. As mentioned before, the same techniques can be used on other
manufacturers analog exciters.

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Reference
[1] 16 Reasons to Replace Rotating Exciters with Digital Static Exciters. Basler
Electric Company. Publication #EX-REP. (March 2002).
[2] MGR Excitation System for generators that require up to 150kW of excitation.
Westinghouse Electric Corporation. Publication #ECE-9107.
[3] Asbury, Gene P. Modern Digital Controllers Provide Additional Features to
Improve Hydro Generators Reliability. Hydrovision, Denver, Colorado. Basler
Electric Company. (2013)
[4] NERC Standards VAR-002-1a. Generator Operation for Maintaining Network
Voltage Schedules. (August 1, 2007).
[5] Buscher, Dale. "Avoiding loss of voltage sensing runaway for generator excitation
systems". Pulp and Paper Industry Technical Conference (PPIC), Conference
Record of 2011 Annual IEEE, pp.120, 123. (June 19-23, 2011).
[6] IEEE standard 421.5-2005, IEEE Recommended Practice for Excitation System
Models for Power System Stability Study (2005).
[7] Kral, David S., and Richard C. Schaefer. "Easing NERC Testing with New Digital
Excitation Systems." Basler Electric. (August 2008).
[8] N.E.R.C. Standards PRC-019-1. Coordination of Generating unit or Plant
Capabilities, Voltage Regulating Controls, and Protection
[9] Kim, Kiyong; Rao, P.; Burnworth, J. "Self-Tuning of the PID Controller for a
Digital Excitation Control System," Industry Applications Society Annual Meeting,
2009. IEEE-IAS. pp.1, 8, 4-8 Basler Electric Company (October 2009).
[10] Schaefer, Richard C.; Kiyong Kim, Digital Excitation System Provides Enhanced
Tuning Over Analog Systems. Basler Electric Company.
Biography
Gene Asbury (IEEE member), has been a Senior Application Specialist for Basler
Electric Company, in Highland IL, since 2006. He has performed in various capacities
since he started with Basler Electric in 1987: Quality Control Supervisor, Technical
Sales Specialist, Project Coordinator, Proposal Engineer, and Application Specialist for
Excitation Systems. Gene attended Southwestern Illinois College and received degrees
in Industrial Technology and Communication Electronics.

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If you have any questions or need

additional information, please contact

Basler Electric Company

No. 59 Heshun Road Loufeng District (N),

Suzhou Industrial Park, 215122, Suzhou, P.R.China
Tel +86(0)512 8227 2888 Fax +86(0)512 8227 2887
e-mail: [email protected]

www.basler.com

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