Sliprings Carbon Brushes Turbo Alternators
Sliprings Carbon Brushes Turbo Alternators
on turbo alternators
Morgan Advanced Materials
Morgan Advanced Materials is a global materials engineering company which designs and
manufactures a wide range of high specification products with extraordinary properties, across
multiple sectors and geographies.
From an extensive range of advanced materials we produce components, assemblies and systems
that deliver significantly enhanced performance for our customers products and processes.
Our engineered solutions are produced to very high tolerances and many are designed for use
in extreme environments.
The Company thrives on breakthrough innovation. Our materials scientists and applications
engineers work in close collaboration with customers to create outstanding, highly differentiated
products that perform more efficiently, more reliably and for longer.
Morgan Advanced Materials has a global presence with more than 10,000 employees across 50
countries serving specialist markets in the energy, transport, healthcare, electronics, security
and defence, petrochemical and industrial sectors. It is listed on the London Stock Exchange in
the engineering sector.
Contents
Sliprings and carbon brushes on turbo-alternators 3
Introduction 4
Surface film 5
Oxide 6
Graphite 6
Humidity 7
Polarity effect on film 8
Slipring materials 12
Helical grooving 12
Electrical contact 14
Ghosting 15
Brush wear 16
Inspections and maintenance 17
2
Sliprings and carbon brushes on turbo-alternators
This brochure discusses the technical background of carbon brushes and sliprings of turbo-alternators;
one of the more difficult applications of carbon brushes in electrical machines.
Morgan Advanced Materials is the worlds largest manufacturer of carbon products for electrical
applications. Within the Carbon Division, National and Morganite are world leaders in the
manufacture of carbon brushes on sliprings of turbo-alternators.
The experience and knowledge of our team of application engineers was used in the preparation of this
brochure.
We are the recognised number one supplier of carbon brushes into the power generation market
and we offer quality high performance generator carbon brushes to support your applications. The
optimum grade for turbo alternator applications is National 634 brush which we manufacture and supply
and is recognised as the industry standard for this application.
The products we offer are:
Carbon brushes Low and stable friction
Carbon brush holders Assists in Preventing ghosting on ring surfaces
Slip rings Proven long life capability
Commutators Excellent current sharing capabilities
Diagnostics for motors and generators.. Consistent contact drop
Reliable and consistent performance Available to fit any generator
Low wear of both brush and slip ring surface Consistent material processing globally
Minimal Polarity wear differences
3
Introduction
A turbo-alternator is a turbine driven synchronous alternator which is used for power
generation in either industry or by power companies.
The turbine runs at a constant speed of 3000 or 3600 RPM, The carbon brushes which are used on the sliprings provide
depending on the required frequency of the alternator a stable electrical contact, whilst carrying high currents, at
output (50 or 60 Hz). a high surface speed exceeding 250 km/hr. This must be
achieved without damaging the sliprings and with reasonably
The DC excitation current of the rotor is often supplied long brush life.
through two (sets of) sliprings on the alternator shaft.
National grade 634, which is normally used for this
The excitation current, depending on the size of the turbo application is a bonded natural graphite material.
alternator, could be as high as 5000 Amps.
It sets the world standard for carbon brush performance on
At 3000 or 3600 RPM the surface speed of the sliprings is turbo alternators.
normally quite high. A speed of 80 m/sec (16,000 ft/min) is
not exceptional.
4
Surface film
During operation a protective film or patina is automatically
formed on the surface of the slipring which plays a very
important role in conducting the current and lowering the
friction reducing brush wear to the lowest possible level.
The film is essential to ensure optimum operation of the
brushes.
This very thin film, only about 20 (2 x 10-7cm) thickness
consists of:
oxide of the slipring material
moisture (water)
graphite
Conducting spots
Current flow
The flow of the current from the carbon brush to the ring There is a thin layer of oxide and moisture between the
is through a small number of contact points which carry sliding surfaces through which current passes by means of
the full current load. The contact points are balanced by a tunnel effect arising through metallic adhesion and film
an equilibrium between the tendency of the brush and breakdown. Shear forces or oxidation result in eventual
collector surface to oxidize and the abrasion of the brush breakdown of these contact points. New contact points are
against the slipring surface. constantly being formed and eroded across the brush face.
Thus we can say that the current flow between a carbon
brush and slipring occurs through a constantly changing,
small number of contact points.
The basic elements of the film, which are oxide, water and
graphite, will now be further discussed.
contact point
carbon brush
tunnel
graphite/water
oxide
slipring
5
Surface film (continued)
Oxide Graphite
An oxide film on steel is more porous, more abrasive, and Studies show that the graphite layer plays the major role in
forms faster than on copper. reducing friction and wear in addition to improving contact.
The speed of oxide formation depends on the temperature, The graphite particles fill the recesses on the slipring surface,
current and specific atmospheric contaminants. in a layered or shingled manner. They have a random
oriented structure next to the metal and a cone pointing
Temperature orientation 10 20 degrees in the direction of sliding on
At a higher temperature the slipring material tends to oxidise the sliding surface. The layers are held together by adhesive
faster than at a low temperature. forces which are higher than the friction force between the
brush and the ring, provided that there is enough moisture
The best ring temperature during operation is 60 - 90 C. on the sliding surface.
It is also very important that the temperature is the same
across the whole surface of the slipring.
Different temperatures not only cause different thickness
of oxide layers, but also affects the current distribution
between brushes.
Therefore the cooling air of the slipring compartment has
to flow in such a way, that the same cooling properties are
achieved across the slipring surface.
rotation
Sometimes air turbulence is created by obstacles in the
airflow path. Because of this, part of the ring becomes less
cooled than others. As a result ring wear, selective action, or
even worse burnt cables can be the result.
Graphite near slipring
The temperature rise of the slipring is approx. 90% caused
by the friction and only 10% by electrical losses.
Current
The ionised metal gas that conducts the current in a
conducting spot transforms into a little bit of oxide. This
is how in general, oxide formation is improved when the
current density is higher.
On cathodic or negative brushes this effect is much stronger
due to electrolysis. On positive brushes the current causes a rotation
roughening of the slipring surface.
Graphite near sliding surface
This will be further discussed in paragraph 3, polarity effect
on the film.
Contaminants
The presence of oil, dirt, dust, smoke, silicones in free form
or oxidising gases can reduce or increase the formation
of the oxide layer. More details are given in paragraph 9,
inspections and maintenance.
6
Humidity
Another important ingredient in the film is water, which The absolute humidity can be found using the
lowers friction. The humidity in the air normally provides following chart.
this water which is needed to reduce the friction to an
acceptable low level. HUMIDITY
In very low temperature conditions the absolute humidity and
of the air will be too low. Brush Life
This will cause high brush wear and increase ring 120 50
temperature. 110
45
40
If the absolute humidity drops below 4.5 g/m3 (grams/cubic 100
SAFE ZONE 35
metre) friction will increase, causing severe brush problems. 90
for brush 30
80
If humidity exceeds 25 g/m3 over filming may occur. Operation 25
70 20
60 15
50 10
40 DANGER ZONE 5
Humidity Too Low 0
30
-5
20
0 10 20 30 40 50 60 70 80 90 100
Percent Relative Humidity
7
Polarity effect on the film
The film on a positive low carbon steel slipring normally appears to be lighter, the ring
temperature higher and the brush wear higher than on the negative low carbon steel slipring.
CURRENT
negative brush
8
As discussed in paragraph 2, the current flows through a Current direction and formation of oxide
limited number of continuously changing spots, which occur
If a current flows between the brush and the ring an electric
where the film is the thinnest.
field is created across the film.
This field does not exist where the actual current flows
(tunnels or spots).
carbon
brush
brush
electronic
graphite/
water
field across
oxide the film
slipring graphite/water
current
oxide
current slipring
In DC motors the oxide part of the film plays an important
role, as it controls the voltage drop in the film, and thereby no electronic field
the commutation properties. In the case of a ring with one polarity, such as in turbo
If the oxide layer is thin, the voltage drop is low which has alternators, the metal will continuously form ions and
negative effects on the commutation properties. electrons under the negative brush.
Too thick an oxide layer will make the formation of For steel this means:
conducting spots difficult, resulting in violent current flow, Fe Fe2+ + 2e or
film stripping and high friction.
Fe2+ Fe3+ + 1e
On a slipring, ideally the oxide layer should be thin and
the graphite part of the film should be dominant (no The electric field under the negative brush will cause the
commutation properties required). positive Fe2+ or Fe3+ ions to move from the collector
surface into the film where they will form Fe0 or Fe 0 with
2 3
This is because graphite reduces the friction and is a better the moisture in the film.
current conductor than oxide.
9
Polarity effect on the film (continued)
The electrons are pushed in the other direction. The positive brushes riding on a low carbon steel slipring
deposit carbon, which, at point contact temperature, lowers
the melting point of steel. This results in minute pools of
brush molten steel existing over an extremely short time span, but
ever changing under the brush, producing a rougher surface
than normal, a lower voltage drop and a higher friction.
Fe2+ + H 0 FeO + H A low carbon content steel normally contains 0.15 to
2 2
2Fe3+ + 3H 0 Fe O + 3H 0.20% carbon. The melting point of low carbon steel is
2 2 3 2
approx. 400C lower than normal when an additive carbon
content has reached 4.3%. Thus as the carbon content
slipring increases from original 0.20% to 4.3%, the melting point
Fe Fe2+ + 2e
current gradually reduces over the 400C drop.
Fe2+ Fe3+ + 1e
The phenomenon of Case Hardening of low carbon steel
involves increasing the carbon content at the surface. This
Negative brush is achieved by heating the steel to a temperature below its
melting point in the presence of carbon (in our case ions
For the positive brush the electric field is in the
from the brush), which gradually penetrates, diffuses or
opposite direction. Under the brush no metal ions
absorbs into the steel thus increasing the carbon content
are pulled into the film and therefore there will be
at the surface. The hardness is due to a chemical reaction
no additional oxidation under this brush.
between the iron and manganese elements and carbon to
form carbides which are very hard (similar to cutting tools).
The carbon brush usage is therefore both chemical and
physical (surface roughness).
brush
Also a shiny surface and not a black graphite surface of
the ring is normally seen under the positive brush being
C C evidence of a definite change in ring composition at the
surface.
The above described effects will only occur on low carbon
steel rings. All other ring materials will not show this effect.
slipring In these cases the brush and ring wear will be higher on
the negative side due to the oxide formation as described
current
previously.
Positive brush
On low carbon steel rings the brush wear on
positive rings is caused by other effects.
10
Conclusion for low carbon steel rings only
Summary:
The negative brush (cathodic)
Under the negative brush additional metal oxide will be Low carbon steel rings:
formed. Positive ring:
The film on the negative slipring contains therefore more
higher brush wear
oxide and less graphite and has a higher voltage drop. lower voltage drop
The oxide film, which is abrasive, creates friction for the higher friction
brush and therefore brush wear.
Brass or other rings:
The positive brush (anodic) Negative ring:
The rough spots are created by carbon deposited onto the
higher brush wear
steel surface, lowering the melting point, creating miniature higher voltage drop
melting pools and case hardening. higher friction
Due to this hard, rough surface and metal picked up in the As mentioned earlier for steel rings, a difference in
brush face, friction is higher. wear rate of 5: 1 is no exception.
Therefore brush wear is higher on the positive ring than on The difference in wear rate can be reduced
the negative ring. considerably by frequently changing the polarity.
Once a graphite film is formed on a ring the graphite
layer stays intact for quite a while when polarity is
changed.
A well accepted procedure, starting with new or
recently ground sliprings is to change polarity with
increasing time intervals such as:
Interval
2 weeks
4 weeks
8 weeks
16 weeks
32 weeks
After this total period of 32 weeks the polarity
should be changed at an interval of one year.
11
Slipring materials
Some of the materials used for sliprings in general are: The alloyed steel used for turbo alternators usually contains:
Alloyed steel
High speed applications
Materials like brass (Cu+Zn) and aluminium are not
suitable for sliprings.
12
It is desirable, however, that the area of the brush in
contact with the ring should not fluctuate widely during the 4.000
traverse of the groove under the brush. This suggests that
the pitch of the groove should be related to the brush a
PRESSURE N-m
(axial) dimension rather than to the width of the ring, 3.000
i.e. the brush a dimension should be an exact multiple
of the groove pitch.
2.000
When a ring is helically grooved, there is an apparent
reduction in the contact area between brush and ring and
therefore it would be reasonable to calculate the contact
1.000
force on the apparent contact area between brush and ring,
i.e., the cross sectional area of the brush less the area of the
groove under the brush. However, the second effect of the
grooving must be taken into account, i.e. the absence of a 10 20 30
gas layer between brush and ring. As a result of the absence
of this gas layer, the brush seats down more closely to BRUSH WIDTH
the ring surface to give a lower contact voltage drop but a
higher coefficient of friction. Slotted brush face reduces
pressure to
In general the lower electrical heat loss counter balances
the higher mechanical heat loss and therefore the contact
force on the brush should be calculated on the full cross
sectional area of brush. Furthermore, it is preferable to 1.5
apply the full contact force to give more mechanical stability
BRUSH WEAR
4(-)
to the brush. 3(-)
Conversely for slower speed, non-turbo applications where 1.0
the pitch of a helically grooved slipring can effectively
remove up to 40% of the brush face area, a reduction in
spring pressure maybe beneficial in preserving brush or 0.5 2(+)
slipring longevity. In these lower surface speed applications
1(+)
there is likely to be no air cushion and therefore the losses
remain the same. The reduction in effective area can
sometimes lead to an increase in brush pressure to levels in
excess of carbon brush manufacturers specifications. TIME
13
Electrical contact
With often more then 50 carbon brushes working in parallel, the electrical contact and
thereby the uniform distribution of current is extremely important.
Some of the elements that affect the electrical contact are:
total wear
A build up of dust, or any disturbance of the brush holder
pocket, could cause the brush to stick in the holder, reducing
mechanical
the contact pressure with the ring and increasing the brush
wear (electrical wear or sparking). electrical
The brush holder and gear must be mechanically very
stable. BRUSH PRESSURE
The distance between brush pocket (holder) and ring should
be between 2 and 3 mm.
It has been found that in general a brush pressure of
It has been found that brushes perform better when 160-180 g/cm2 is the optimum for grade 634 on turbo
operating in a slightly trailing position. alternator applications.
An angle of approx. 2.5 is enough. The brush pressure should be checked regularly.
A stubbing position must be avoided as it increases the The maximum allowable difference between individual
tendency to vibrate. brushes should be below 10%.
2.5
Other electrical connections
All electrical connections between main busbar and brush
body must have a low resistivity and should be equal for
parallel conductors.
A critical electrical connection is the one between brush
and cable.
Two of the most common connection technologies are
riveted connections or tamped connections.
Studies have shown that a modern tamped connection is
rotation thermally more stable than the riveted one.
14
Ghosting
One effect frequently seen on sliprings of turbo alternators is called ghosting, also called
ghost marks.
A ghost mark can best be described as an imprint of
the brush on the slipring. The imprint, with the same
dimensions of the brush has a somewhat rougher surface.
It appears as if material is etched away see photograph
showing Ghosting on rings back cover.
These are two causes for ghost marks which are:
1. During operation of the turbo alternator a momentary
extreme high current peak occurs in the excitation
current (high dl/dt).
The number of contact points at the brush surface are It is therefore recommended that, when a machine
insufficient to carry this sudden high current load. The is stopped for a longer period of time, brushes are
effect is a violent current flow with heavy ionisation and removed from the holders or lifted away from the
arcing. The result is a burnt spot with the exact brush slipring surface.
width and thickness.
In most cases turbo alternators, when not in use, are
This instantaneous current surge can occur when: turned at very low speed. In this case brushes do not
There has been a short circuit in the AC system.
have to be removed.
a large asynchronous motor was started in the power When ghost marks have developed on a slipring they
plant with a high starting current. tend to develop into larger rough spots because of
alternators were switched without being quite spark erosion. Every time the spot passes a brush some
synchronised. sparking will be seen.
2. Another type of ghost marking can occur after a turbo This phenomena will not automatically improve and the
alternator has been standing still for a number of weeks. slipring has to be reground to restore performance.
Different metals in the alternator circuit create a galvanic
cell, that can cause closed loop currents to flow.
Electrolysis as discussed in section 3, polarity effect, Beginning of Ghostmark
will then oxidise the ring under the brush with the exact
brush dimensions.
direction of
rotation
slipring slipring
15
Brushwear
The brush wear of grade 634 on turbo alternators As a general rule we can say that:
depends on various conditions such as:
<5 mm/1000 hrs is very good
current load
5-10 mm/1000 hrs is good
surface speed
11-20 mm/1000 hrs is acceptable
brush pressure
>20 mm/l000 hrs needs attention
temperature
contamination Optimum operating conditions for grade 634 are:
condition of the ring
Current density: 5.5 - 8 A/cm2
Surface speed: 45 - 80 m/sec
Abs humidity: 8 - 13 g/m3
Slipring temp.: 60 - 90C
Brush pressure: 160 - 200 g/cm2
16
Inspections and maintenance
Brushes, holders and sliprings need to be inspected regularly. A problem found at an early stage
can often be corrected easily. At a later stage it can lead to severe damage and expensive repairs.
Inspection checklist
Brushes Brushholders
Brush length Periodically the brush holders have to be checked.
Make sure there are no brushes in operation which are too Important points are:
short.
Brush pocket
Cables
Make sure the brush pocket is not damaged and brushes
Check cables for discolouration or broken wires due to
can move freely.
vibration or other types of wear.
Electrical connections, such as the brush terminal
If some brushes are found with discoloured cables this
could be a sign of selective action. The current density Make sure this connection is clean and as tight as possible.
in the discoloured cables has been much too high. It
is recommended that the complete set of brushes are Holders designed for on-load brush changing need extra
changed if severe selective action has taken place as the attention. The connection surfaces must be very clean and
brush connections may have been damaged by the high undamaged.
currents. Note: Brush holders should never be cleaned using sand
Sometimes groups of wires in the flexible cables break due blasting or similar methods.
to vibrations or the continuous motion due to strong cooling Sand blasting creates a rough surface inside the brush
air flow. pocket which has a negative effect on the free movement
If more than 10% of the cable is affected the brush should of the brush.
be replaced. Brush springs
Vibration marks Check the springs periodically and replace those which
If the brush shows highly polished areas on the sides, this is deviate more than 10% from the correct force.
an indication of excessive movement in the holder pocket. Distance between holder pocket and slipring
This phenomena is caused by eccentric rings or high friction. Brush holders should ideally be set at 2-3mm from the
Also check the sides of the brush for erosion due to current slipring surface. Distances greater than this could lead to
flowing between brush and holder. (If this is suspected then brush instability and possible damage.
the brush connections might be damaged and new brushes
are recommended) Sliprings
Frequently check for any type of damage which could affect
Brush face
the electrical contact.
Check the brush face for:
When the machine is running this could be done with a
Chips: caused by handling or other mechanical impact. stroboscope adjusted to a frequency not exactly the same
as the turbine speed.
Rough surface: probably caused by spark erosion due to
too low brush pressure or bad electrical contact between This makes it easier for the human eye to inspect.
the brush and ring in general.
17
Inspections and maintenance (continued)
Slipring compartment Humidity
Inspect the whole compartment, looking for traces of oil. Especially in areas where low humidity can be expected
such as a higher altitude or at places with cold winters,
If oil, leaking from a bearing gets into the slipring film, a humidity must be checked regularly. If low humidity (below
highly polished layer is formed, causing high friction and 4.5 g/m3) and high friction is found, excitation power and
high brush wear and possible jamming of the brushes in the therefore the output power of the alternator has to be
brush holders. reduced to compensate for the high friction heat build-up.
Grey streaky spots on the slipring are a sign of this. A medium to long term solution to improve the situation is
Carbon brushes are porous and will therefore soak up oil. If to inject some steam into the cooling air inlet system. This
an oil leak developed and the brush gear was exposed to it, will increase the humidity and therefore reduce the friction
it is recommended to replace all brushes, and to thoroughly again.
clean down all brush holders, springs and connection points. Steam injection must be stopped when humidity reaches a
Signs of sparking normal level again. In places where low humidity regularly
causes friction problems, automatically controlled humidifiers
Heavy sparking could result in a flashover between different are placed in the cooling air inlet system.
polarity.
Signs of heavy sparking can be found on brush holders, Slipring roundness
brush gear or other places in the slipring compartment, then When vibration marks are found on the brushes and some
further checks should be made to determine and correct sparking is noticed, the roundness of the rings must be
the cause. checked.
Dust Both manual devices such as dial indicators, as well as
electronic slipring profiling units are capable of providing
Carbon dust is a good conductor of electricity.
accurate indications of ring concentricity.
Excessive buildup of carbon dust could lead to a flashover
A sensor is placed in the brush pocket which is connected to
between rings of different polarity. the microprocessor based meter.
It is therefore recommended to clean the slipring After the shaft is turned, a print-out can be made of the
compartment regularly, using a soft bristle brush to loosen slipring profile.
the dust and then a vacuum cleaner to remove the dust.
If the slipring is more than 0.05 mm out of round the ring
Brush temperature should be ground.
It is important to check the brush temperatures regularly. Grinding is a specialists job using special grinding stones and
Too a high differential indicates possible selective action a support.
leading to different brush wear, or worse, burnt cables or
connections. Grinding by hand will likely make the problem worse.
18
19
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Morgan Advanced Materials is a global engineering company offering world-leading competencies in materials
science, specialist manufacturing and applications engineering.
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