GENERATORTECH, INC.

Generator Rotor Winding

Shorted Turn Detection
Products and Services

Air-Gap Flux Probes

Rotor Winding Shorted Turn Analysis Systems

Installation and Testing Services

On-Site Training
 Shortedturns
Shorted turns——Why
Whydo
doyou
youneed
needtotoknow?
know?
Generator problems must often be solved by process of elimination.
Having an accurate assessment of your rotor windings provides an
excellent starting point on the path to correctly identifying and solving
generator problems.

Shorted turns are generally caused by failed insulation between individual

windings in generator rotors. Stop-Start cycles, line disturbances,
contamination, moisture, manufacturer error and damage during retaining
ring installation are some of the reasons insulation fails.

The impact of operating with shorted turns ranges from no-problem to

abnormal vibration, load limits, higher operating temperatures and forced
outages. Generatortech, Inc. specializes in shorted turn detection and
can help plant operators and engineers pinpoint the cause of
abnormal vibration, assist in major maintenance decisions and verify the
Figure 1: End-strap elongation has distorted quality of new and rewound rotors.
the top turn of the #6 coil resulting in contact
with the top turn of the #7 coil. Shorted turns often develop over time. Regular testing of your rotor
windings allows you to actively monitor the field windings, providing
valuable information for your predictive maintenance plans.

Generatortech Data Acquisition & Analysis Program

The Industry’s Gold Standard
The Data Acquisition & Analysis Program is the center
of Generatortech’s rotor winding shorted turn diagnostic
toolset. The software is extremely intuitive and easy-to-
use. The analysis algorithms have been fine-tuned by
over two decades of experience with field windings
shorted turns. Generator manufacturers, service
companies and power producers have been utilizing
Generatortech’s Data Acquisition & Analysis Program
throughout the world in order to meet their rotor shorted
turn detection needs.
Generatortech offers free technical support for all
purchasers of the Data Acquisition & Analysis System.
Customers are encouraged to forward their data to
Generatortech for peer review.

Shorted Turn Testing Methodology

• A permanent air-gap flux probe is installed on a stator wedge near the turbine end
of the generator. The signal cable is routed out of the generator through a casing
gland which has an integral BNC test connection. (see Figure 2)
• Generatortech’s portable or permanently mounted analysis system is connected
to the BNC test connection for data acquisition.
• Data is taken at various loads to maximize resolution of the analysis for each coil
in the rotor field winding. Optimum testing, especially for baseline tests requires
taking data at approximately 12 loads points ranging from 0% to 100% load.
• The Generatortech Data Acquisition and Analysis program analyzes the data
which is then reviewed and evaluated by trained personnel to determine rotor
winding status.
• Data is normally acquired and analyzed at six-month intervals or yearly, or more
frequently if operating conditions give cause for concern or shorted turns have
developed since previous testing. Figure 2
 Generatortech Products
Permanent Air-Gap Flux Probes are custom
designed and fabricated for each application. The correct flux probe
dimensional and sensitivity parameters are essential for obtaining
signals that can be used for analysis. A variety of available models
and construction materials are used to design and build the optimum
flux probe for each generator. Generatortech flux probe materials are
impervious to the normally harsh environment within the generator
and should last for the life of the stator. All probes come with casing
glands.

Temporary Air-Gap Flux Probes are available for hydrogen and air cooled machines. Temporary probes
are inserted through a stator ventilation slot into the air gap.

BNC Signal Cable Connector

3/16” SS Probe

Portable Analysis System

The Generatortech Model 9610 Portable Analysis System has been the data collection and analysis “workhorse” for the
rotor shorted turn detection field since the late 1980’s. Available with or without a portable laptop computer, the system
comes packaged in a rugged, wheeled carry case for maximum protection and portability. Our newest version of the
Generatortech Data Acquisition and Analysis Program provides:

• Improved graph and data charts.

• Ability to preload generator setup information for up
to 14 units.
• All Charts & Graphs can be created as .JPG files.
• The analysis curve can be displayed while digitizing
& acquiring test data.
• Test data can be auto-saved at optimum load points.

NEW! Permanent Analysis System

The Generatortech Model G50 Remote Analysis System
is the latest development for rotor shorted turn detection
providing for 24/7 continuous data collection.
Using the same, time-tested, Generatortech Data
Acquisition and Analysis Program that our portable
system uses, the Model G50 is a rack mounted system
designed to simultaneously monitor up to four generators.
A generator’s flux probe is permanently connected to the
G50 which can be accessed via Internet or your company
intranet using a secure VPN connection. The G50 allows
test data to be acquired automatically and/or manually.
No need for your staff to travel to distant power stations
for testing. In fact, Generatortech can provide contracted
services to be responsible for your regularly scheduled
testing and analysis.
 Generatortech Services
Today’s competitive electrical power market requires data-driven, cost-effective maintenance decisions.
Superior data and analysis are needed to make optimal maintenance decisions. Generatortech provides the
information needed to decide when and if your generator rotor needs repair. Generatortech’s varied support
and equipment options can be tailored to accommodate our customer’s needs.

Build & Install

• Permanent flux probes
• Temporary flux probes
On-Site Testing
• Generatortech engineering technicians perform on-site testing and analysis with follow-up reporting.
• Generatortech rents testing equipment for data acquisition by plant personnel. Data is emailed to Generatortech
for analysis.
Generatortech Acquisition & Analysis Packages
Purchase a complete Generatortech Acquisition & Analysis package so your engineers can test and analyze your
generators.
• Purchase the Model 9610 Portable Data Acquisition & Analysis System, available with or without a laptop
computer.
• Purchase the Model G50 Remote Data Analysis System. Up to four generators are permanently
connected to the consolidated air-gap flux probe signal conditioner. The remote system allows
monitoring via secure VPN Internet connectivity.
• Purchase the Model G50 Remote Data Analysis System with Generatortech monitoring option.
Generatortech will provide regular testing and shorted turn analysis reporting using a VPN connection
to your G50.
Training/Symposiums/Consultations
• Generatortech Air-gap Flux Probe and Shorted Turn training classes and symposiums can be scheduled for
staff, engineers and management. Generatortech staff are always available for phone consultations.

Compare Testing Methods

Technique Location of Turns Sensitive Quantitative Detects Speed/Thermal Dependant Shorts

OFF-LINE TESTS
Rotor Impedance Test NO LOW NO Yes-speed, voltage
Pole/Cole/Turn Voltage Drop Test YES HIGH YES NO
Search Coil Slot Flux Distribution Test YES HIGH NO NO
ON-LINE TESTS
V/A Measurements NO LOW NO maybe

GENERATORTECH FLUX PROBE TEST YES HIGH YES YES

Our customer list includes:

Established in 1989, • Power generating utilities and cogeneration industries worldwide including
Generatortech, Inc. is the turbine and hydro generators.
world leader in the detection • Service companies, who use our probes & analysis software for spin pit testing
and provide retrofit installations.
of rotor winding
• Original Equipment Manufacturers (OEM) - install Generatortech equipment
shorted turns. in new generators and as retrofit applications during major outages.

GENERATORTECH, INC.
[email protected] 1.518.399.4646 phone & fax
www.generatortech.com
31 Sutherland Drive
Scotia, New York USA 12302-5421