CORE FLUX TEST

OBJECTIVE:
The core flux test is a high-energy test used to check the integrity of the insulation between the
laminations in the stator core.
1. To know change in core losses due to deterioration of core insulation of generator
due to continuous operation.
2. During testing local hot-spot is also inspected, which indicates position of
insulation deterioration.

CORE LOSSES:

Hysteresis Losses:
Hysteresis loss is the amount of input energy expended to change the magnetic polarity of the
steel in conjunction with the changing polarity of the alternating current waveform.

Eddy Current Losses:

The losses due to circulation of eddy current. Eddy currents are circulating currents resulting
from the magnetic fields generated in the generator.

Change in Eddy current Losses:

When any electrical conductor is placed within a magnetic field, a current proportional to the
cross-section of the conductor and the strength of the field is known to flow perpendicular to that
field. For this reason, steel lamination thickness is minimized to reduce the amount of eddy
current flow.

When the insulation between laminations breaks down, there is an associated increase in the
eddy current flow. At the point of degradation, currents flow between the laminations as shown
in Figure. Eddy current loss is the total input power lost to these circulating currents.
Core Flux Test with Infrared Scan:
It is also commonly referred to as the ring flux test, in which near-rated flux (normally about
80%) is induced in the stator core yoke. This in turn induces circulating currents and excessive
heating in areas where the stator iron is damaged. The heat produced is detected and quantified
using established infrared techniques. Flux is produced in the iron by looping a cable around the
core in toroidal fashion, and circulating a current at operating frequency. The flux required for
the flux test is half the normal operating flux due to the difference in the way the flux is induced
in operation from that of the flux test.

The power supply for the cable is usually taken from two phases of one of the high-voltage
breakers in the plant, or a portable motor generator set. The correct number of turns are looped
around the core to produce the required level of flux.

The flux voltage (Vf) required for rated flux in the back of the core is:

Vf = VL-L
2√3 x Kw x N

where
VL-L = Line-to-line voltage
Kw = winding factor
N = number of turns per phase in series in the stator winding
As the equation shows, the available power supply voltage is divided by the calculated volts per
turn above, to give the correct number of turns to loop through the core. If the number of turns
includes a fraction, then the next highest number is used, to reduce the flux level to below 100%
or below rated. Using too high of a flux level can create core damage, since there is no cooling
on the core during the test.
Once the number of turns is known, the current capacity is required to size the cable and ensure
the power source can handle the current that will be drawn.
Knowledge of the specific B-H characteristic of the subject core being tested is required for this.
In many instances it is unknown, and therefore the number of ampere-turns required must be
estimated based on industry curves for the most likely grade of core-plate that will be used in the
machine under the test. A higher end and lower end core-plate grade are usually selected to
provide a range of possible operating characteristics for the subject core.

From the winding configuration for the subject generator, the power supply available, and the B-
H curves, an estimate can be made for the number of turns required to achieve the required level
of flux for the test. This is generally in the 80 to 90% range of rated flux. The current that would
be flowing in the flux cable will depend on the actual B-H characteristic of the stator iron and
therefore, this must be carefully estimated for safety of both personnel and the equipment.

Test Set-up

The power supply is selected and connected as shown. The cable is wound through the stator
bore the correct number of times, and connected back to the power supply. Protection for the test
cable is set up to provide “ground fault” and “overcurrent.” The stator core, frame, and windings
were all grounded for their protection and that of the test personnel. The CTs should also shorted
at the terminals and grounded. Metering is set up to provide measurements of supply voltage and
current. A single loop of cable is installed additionally to measure the actual flux volts on the
stator core during the test. This is done to provide an accurate measurement of the induce voltage
across the core and the level of flux as well.
In some cases an infrared is used to monitor the temperature of the stator core when angled
viewing from outside the stator. Once the flux is established in the core, it is kept for at least 30
minutes to 1 hour. The temperature of the core should be maintained within values not
significantly higher than those encountered during operation. Under these conditions the
temperature rises in the core are monitored and recorded while the existence of hot spots is
investigated with infrared monitoring equipment. The temperature rises of the “good” core areas
(ambient core temperature rise) are then compared to the temperature rise profile of any
defective locations found. Once the defects are located and characterized, repair solutions can
then be addressed.

Questionnaire:

1. What is hysteresis loss?

2. What is eddy current loss?
3. Why eddy current loss increases with time?
4. What condition should be maintained during test to create actual running
condition in respect to core losses?
5. What is magnetizing current?
6. What is winding factor?