Testing of

Generator and
its
components
1
INTRODUCTION TO
TESTING STRATEGIES

In this presentation, we will learn

about types of tests performed on
generator and its components
like Stator its Winding and core,
Generator rotor, Exciter rotor, and
PMG

Relevant testing standards and

reports are discussed in detail for
comprehensive enrichment.
 Brief Overview

Generator Stator Generator Stator PMG

Rotor Winding Exciter
Winding core

• IR and PI • Digital ELCID • Insulation Resistance • Insulation Resistance • Insulation Resistance

• Tan delta and • Baroscopic/endoscopic • DC Winding resistance • DC winding resistance • DC Winding resistance
capacitance inspection • AC Impedance test • Voltage balance/Pole
• Partial discharge • Digital RSO drop
• DC winding resistance • Pole drop • Q axis Checking(IR and
• Wedge tightness DCWR)
• Exciter Stator(IR and
checking
• Natural frequency test DCWR)
• Baroscopic/endoscopic
• RTD element checking
inspection
 Standard
IR & PI IEEE 43-2013

Insulation Resistance (IR):

 Measures the ability of winding insulation to resist DC current
leakage.
 Defined as the ratio of applied DC voltage to resultant current.
 Helps detect insulation cracks, surface contamination, moisture,
and thermal deterioration.
 Useful for monitoring insulation health trends.
Polarization Index (PI):
 Assesses winding cleanliness and impurity levels by measuring
leakage current behavior over time.
 Defined as the ratio of insulation resistance at 10 minutes to that
at 1 minute.
 Formula: PI = IR (10 min) / IR (1 min)
 Recommended to test each phase separately with external
equipment disconnected to avoid interference.
Acceptable IR & PI Values (IEC 43:2013 Guidelines)
1. Insulation Resistance (IR) – Minimum Acceptable Value
•IR (in MΩ) = kV + 1, where kV is the rated voltage of the machine.
•Example: For a 6.6 kV motor, the minimum IR should be 7.6 MΩ.
2. Polarization Index (PI) – Acceptable Range
For new or well-maintained machines, a PI >2.0 is recommended.

PI Value Condition
<1.0 Poor – Insulation failure risk
1.0 - 1.5 Questionable – Further testing needed
1.5 - 2.0 Fair – Aging insulation, monitor closely
2.0 - 4.0 Good – Healthy insulation
>4.0 Excellent – Clean and dry insulation

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 Tan Delta and Capacitance Measurement

Principle:
An ideal insulator behaves as a pure capacitor when connected between line and
earth. In a perfect dielectric, the current is purely capacitive with no resistive
component, as there are no impurities.

Theory:
Tan delta (δ) measures electrical insulation losses. A lower tan delta value
indicates better insulation quality. In a perfect insulator, tan delta remains
constant with increasing voltage. However, insulation voids in stator windings
can cause partial discharges, increasing electrical losses.

Major Loss Components:

Solid Loss – Dielectric absorption & conductivity
Ionization Loss – Partial discharges
Resistive Loss – Internal coil & external grading losses
The Total Dielectric Loss is the sum of these components and increases with voltage.
Power Factor Tip-Up is calculated between two voltage levels (e.g., 100% UPH & 20%
UPH).
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 IEEE std. 286-2000

Positive Tip-Up: A
significant increase in tan
delta with higher voltage,
indicating insulation
degradation, moisture, or
contamination.

Negative Tip-Up: A
decrease in tan delta with
higher voltage, which is
unusual and could indicate
measurement errors or a
highly stable, low-loss
insulation system.

Sample Test report 7

 Partial Discharge (PD) in Rotating Machines

Description:
Partial discharges (PD) are electrical sparks within insulation gas voids, detectable
through high-voltage capacitors. PD testing assesses insulation health without visual
inspection.

Common PD Causes:
Loose wedges/bar vibration
Cracked conductors
End winding contamination
Corrosion in suppression systems
Insulation degradation

PD Analysis:
Pulse count, magnitude, polarity, phase

Discharge Types:
Internal
External (slot, surface, end winding)
PD testing is key to identifying insulation issues and ensuring machine reliability.
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 DC WINDING RESISTANCE
Description: IEEE118-1978
Winding resistance measurements help diagnose potential generator damage from
poor design, handling, overloading, or inadequate maintenance.

Purpose:
Detect gross differences between windings
Check for open connections Standard

Conversion Formula: 2% variance from

expected is usually an
indication of an abnormal
stator winding circuit

Or as per OEM
recommendation

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 Wedges Deflection test

Insulation packets/ripples are used beneath stator slot

wedges to prevent bar loosening and reduce vibration from
pulsating magnetic forces.

During overhauling, wedge mapping or deflection tests are

performed to check the tightness of the wedges.
Wedge condition is evaluated by applying manual impact or
hydraulic pressure, while observing the vibration and sound
to detect any looseness.

In vacuum impregnated machine wedges nocking method

is used if required.

Slot Wedges

In Stator: Non metallic(as

depicted in picture.
In rotor: Metallic
 Natural Frequency test IEEE 62.2-2004
Or As per OEM
Recommendation

Description:
Measured frequency response of lead coils/end
winding phase rings in stator windings at different
directions.

Assessment:

Natural frequency of end-winding for all coils

measured during the Bump test.
Frequencies near 100 Hz identified for correction and
retest.

For 50 Hz machine: 95-105 Hz is rang of concern

For 60 Hz machine: 115-125 Hz is rang of concern

In case above frequency are observed strengthening

of overhang portion is mandatory.
 Digital ELCID Test IEEE 62.2-2004
Or As per OEM
Recommendation

Purpose: Detects faults in the generator stator core

caused by defective inter-laminar insulation.

Issue: Faults lead to localized circulating currents (eddy

currents), causing overheating and potential core damage.

Digital ELCID Test: Uses only 4% of rated flux to

generate fault currents, offering a safer alternative to high
current/voltage tests.
Test Principle:
Magnetic Field Excitation: Core is excited with a low-
level (4%) ring flux.
Chattock Coil: A coil senses the magnetic potential
gradient on the core surface.
Fault Detection: Measures fault currents magnetically,
avoiding thermal effects.
Digital Output: Converts the analog signal to a digital
form for display/storage on PC.
Benefits:
Effective for trend analysis and predictive maintenance.
Helps prevent severe core damage and insulation failure.
VISUAL INSPECTION
TECHNIQUES

Visual inspections are the ffirst

line of defense in identifying
issues. Inspect components for
wear, corrosion, and loose
connections. Regular visual
checks can prevent more
severe problems and ensure
that the generator operates
smoothly.
 IEEE 62.2-2004
AC Impedance of rotor
Measures the impedance of the winding at a specified
AC frequency.

Helps detect issues like shorted turns, insulation

degradation, contamination, or loose connections.
Identifies changes in impedance that may indicate
insulation deterioration or other internal defects.

Analyse the data is to run it up in 10-volt step,

then run it back down in 10-volt steps. Normally
the data will show some hysteresis, which is
normal and expected. The important part is that
the data start and end at the same point. A
closed path is good which indicates no inter-turn
shorts.
 IEEE 62.2-2004
Digital RSO
Recurrent Surge Oscillograph

Purpose: Detects rotor winding faults, such as shorted turns,

interturn faults, high resistance joints, and earth faults.

Principle: Based on Time Domain Reflectometry (TDR) to analyze

impedance variations.

Test Method:
A low voltage, high-frequency pulse is applied to the rotor winding
circuit.
A shorted turn creates an impedance change, causing reflected
and transmitted waves.
The response characteristics curve of a faulty rotor differs from a
normal one.
Analysis:
The test results are displayed as two superimposed waveforms.
Mismatch in waveforms indicates the presence of faults in the
rotor windings.
Key Benefits:
Non-destructive test method.
Effective in detecting rotor faults without machine disassembly.
DOCUMENTATION AND
REPORTING

Maintaining thorough
documentation of all testing
and maintenance activities is
essential. This ensures that any
issues can be tracked over time
and helps in making informed
decisions regarding repairs and
replacements. Accurate
records enhance operational
efficiency.
 Thanks
!
Do you have any questions?