Table of Contents

Generators

SECTION PAGE #

1. Introduction 1

2. Basic Design 2

3. Malfunction Behavior 16

4. Process Effects 26

5. Mechanical Effects in Generators 28

6. Generator / Exciter Diagnostics 32

7. Diagnostic Methodology Applied to Generators 33

8. Information Required 35

9. Other Diagnostic Tools 37

REV C 129279
Generators—Introduction Page 1

Introduction

Generators are both simple and complicated at the same time. Generators
are simple mechanically in that they have a rotor supported by two bearings. Their
structures are complicated by rotor asymmetry, windings, wedges, cooling slots,
retaining rings, etc. There are a minimal amount of seals, and the rotor does not
experience great temperature changes.

125 MW Generator
STATOR

HYDROGEN SEAL FAN

BEARING

OIL SEALS HYDROGEN

SEAL
RETAINING RING
ROTOR

ENDBELL OUTPUT LEADS

Figure 1. Generator Cross Section Drawing

Under normal circumstances, generators do not experience damage from

erosive steam or solid particles, and their internal operational environment is
usually very clean. By their nature, generators require little maintenance, and are
infrequently opened, so they usually won’t be damaged by people.
REV C 129279
Page 2 Applied Diagnostics

Generators initially may look simple in their design, however, because of all
the windings, wedges, coils, slots, and cooling passages that are required to make
the machine work, they are complicated machines. In order to build a generator
that can generate the amount of power required for a modern generation station,
and make it small and light enough so it can be transported to the site and be able
to withstand thirty years of continuous use, some very sophisticated design work
had to be employed.
Most of the design sophistication went into being able to produce a
generator that would stay cool given all the physical restraint and specifications of
the customer. When a generator is sensitive to load, hydrogen pressure, Volt-
Amperage Reactive (VARS) or phase balance, it may mean that it is thermally
sensitive, it’s not being cooled properly and the rotor is warping due to differential
heating.
What we will cover in the following sections will deal with how the
generator reacts to mechanical and thermal effects, and what you can determine
and do about these influences.

Basic Design

The basic mechanical design of a generator is quite simple. A long slender

shaft is supported by a fluid film bearing at each end. The bearings are usually
supported in a spherical cradle which is mounted in the generator end bells. The
rotor system incorporated in a generator is simple and straightforward.
Nevertheless, one needs to take a closer look at each of the components in the
generator to see how they can affect the generator's vibration response.
REV C 129279
 Generators—Basic Design Page 3

1. Rotors

A. Design/Construction

Most rotors are made from a one piece forging of a very high
purity steel alloy. Some of the biggest rotors are made up of multiple
pieces because the steel foundries cannot produce the multiple
hundred ton forgings required.

Sub Slots Pole Center

Wedge
Field Coil

Coil Slots
Vent Slot Wedge
Cooling Slots Vent Slots
Field Winding

Vent Slot
Turn Separator

Tooth

Sub Slot

Figure 2. Generator Rotor Cross Section Figure 3. Rotor Wedge And Tooth

The electrical and mechanical properties of the rotor forging are

critical to the performance of the generator, so no welding is usually
allowed on the rotor to repair voids or machining errors. The rotor
forgings go through extensive non-destructive testing to assure that
there are no voids or other imperfections that would affect the rotors
mechanical or electrical integrity. Most modern rotors will be of a
REV C 129279
Page 4 Applied Diagnostics

two or four pole design. This means that there will be either two or
four pole centers on the rotor. The pole centers are areas where the
rotor has no windings and is essentially solid from one end of the
rotor to the other. This means that the rotor will have an asymmetric
stiffness that will generate either a two or four times running speed
frequency component depending on weather the rotor is a two pole or
four pole design. In order to minimize the asymmetric stiffness, pole
centers will often be machined with cross slots that run radially
through the pole center. The effect of the cross slots is to reduce the
stiffness of the rotor perpendicular to the pole center's longitudinal
axis.

B. Balancing

Generator rotors are usually factory balanced using balance

holes that run along the length of the rotor. Field balancing is
accomplished by placing weights at the ends of the rotor in specially
machined grooves or at the fan assembly.
A generator rotor (field) is a large rotating electromagnet. Any
unbalance in the pole's magnetic field can also cause a synchronous
vibration to occur.

REV C 129279
Generators—Basic Design Page 5

Cooling passages formed in generator rotor

windings. This area is under the retaining ring.

Figure 4. Rotor Cooling Passage

C. Cooling

Along with the winding slots there are cooling passages formed
in the rotor and in the windings to keep the rotor cool. If the rotor
experiences differential heating, or localized heating, the rotor will
likely bow and show an increase in synchronous vibration.

REV C 129279
Page 6 Applied Diagnostics

125 MW Generator
STATOR

HYDROGEN SEAL FAN

BEARING

OIL SEALS HYDROGEN

SEAL
RETAINING RING
ROTOR

ENDBELL OUTPUT LEADS

Figure 5. Generator Cross Section

2. Stators

There is very little that the stator can do mechanically to create an

unbalance. Electrical unbalance effects, due to disturbance of the magnetic field,
are possible.

A. Design / Construction

The stator core is made from steel which has a high magnetic
permeability, so the magnetic lines of flux can easily travel from one
rotor pole to the other. If there is an interruption in the stator core so
that the lines of flux cannot return properly and the flux field is
distorted, there can be a magnetic unbalance generated. The magnetic
field that moves with the pole centers distorts the stator of a two pole
REV C 129279
Generators—Basic Design Page 7

generator into an oval shape. In order that the resulting twice

rotational frequency components of vibration caused by the distortion
are not transmitted to the generator frame, the stator is stacked on
spring bars that deflect with the stator but do not pass the deflection to
the frame. If these spring bars are loose on the stator iron, the
generator will growl and show a higher than normal casing vibration.
This growling tends to be worse when the generator is cold and slowly
subsides as the generator warms up. The stator vibration response is
related to the magnetic field within the generator.

STATOR CORE DEFLECTION

TO
RQ
UE

TN
RO
MAXIMUM
RADIAL
N S
MOVEMENT

STATOR ROTATING
CORE FIELD

Figure 6. Stator Core Deflection

REV C 129279
Page 8 Applied Diagnostics

The generator output and excitation requirements also depend on the

same magnetic field. Any significant disturbance in the field will be
detectable in the generator output and excitation requirements. Changes in
the magnetic field may also be detected by changes in the generator casing
vibration level.

3. Bearings

The generator bearings are much the same as the turbine bearings and
may cause the same problems as seen in the turbine. Bearings are usually of
the self aligning type. The major difference between turbine and generator
bearings is that at least one of the generator bearings must be insulated, so
that electrical current doesn't pass through the babbitt. If the insulation is
shorted and current starts to pass through the bearing, the babbitt can be
eaten away very quickly by arcing (electrostatic discharge).

Bearing
Endbell

Bearing Cradle

Figure 7. Generator Endbell and Bearing Arrangement

REV C 129279
Generators—Basic Design Page 9

If this situation goes undetected, the bearing can be totally destroyed.

When properly installed and insulated, generator bearings should not cause a
problem. The bearings are supported from the generator endbells, so they
usually do not experience the relative movements that turbine bearings do.

4. Couplings

Figure 8. LP-Gen Coupling

Generators typically have two couplings; one connects the generator to the
turbine and the other connects the generator to the exciter. The turbine-generator
coupling will be the same as that found on the turbine. Couplings are designed and
machined, so when bolted together the friction between the halves will transmit the
load.
REV C 129279
Page 10 Applied Diagnostics

On many modern turbine generators, the coupling bolts are designed to carry
load under normal conditions. This is due to much higher loads and the desire to
keep the coupling diameter small. During system faults, the coupling bolts are
designed to carry the extra load and are normally closely fitted in their holes so the
coupling, faces cannot slip relative to each other. If the coupling bolts are partially
sheared or galled in their holes, usually the only way to remove them is to drill
them out. This process usually results in a rough hole that has to be honed smooth
and then have an oversized bolt fitted. The oversized bolt may be heavier then the
bolt that was removed, and the rotor balance may be affected.

Figure 9. Exciter Coupling

The generator to exciter coupling (if present) does not have to withstand the
forces the generator/turbine coupling does. Consequently, this coupling will be
REV C 129279
Generators—Basic Design Page 11

much smaller and the bolting not so critical. The problem usually encountered
with this coupling is misalignment between the exciter and generator. If these
coupling bolts are not properly tightened, an asymmetry exists between the exciter
and the generator, which may manifest itself in increased vibration levels.

5. Seals

The seals in the generator are designed to keep oil in the general area of the
bearing and out of the generator itself. The hydrogen seals (if used) keep the
hydrogen in the generator. Unlike turbine seals, generator hydrogen seals are not
supposed to touch the shaft as a normal occurrence, but run on a film of oil instead.
Generator oil seals are not set tight and have a defined clearance from the shaft.
Usually, as generators are being reassembled, each part is resistance checked
(meggered) to assure that it is insulated from the generator frame. Hydrogen seals
are lubricated and should be able to move; if locked (stuck), a rub is likely to
occur. Hydrogen seal rubs are known to cause the generator's vibration response to
exhibit large amplitude and phase angle changes.

REV C 129279
Page 12 Applied Diagnostics

Hydrogen Side Gland Seal

Air Side Gland Seal
Gland Seal Float Oil
Gland Seal Rings Labyrinth Seal Rings

Bearing

SHAFT

Air Side

Hydrogen Side
Air Side Seal
Oil Drain Hydrogen Side
Seal Oil Drain

Figure 10. Generator Hydrogen Seal

6. External Strains

When discussing steam turbines, we saw that there were many attachments
(piping, etc.) that could warp and pull the turbine out of place. Generators, as a
rule, don't have anything attached to them that can cause similar effects. Hydrogen
and cooling water piping are small and relatively flexible. The electrical
connections are usually made up with braided flexible links that won't allow any
relative movement between the generator and iso-phase bus to stress the generator
output terminals. In short, there is usually no attachment that can warp the
generator shell or change the bearing alignment.

REV C 129279
Generators—Basic Design Page 13

7. Generator Supports

Generators are not usually bolted rigidly to the pedestal sole plates and are
expected to expand and contract with temperature changes.
When the generator is properly grouted and shimmed, it should not move up
or down, or side to side. The generator should be free to expand axially with
increasing temperature. Generators do not, as a rule, expand very much, but there
is thermal growth that must be allowed for. The changes made to correct
misalignment between the turbine and generator are usually a result of pedestal
movement under either the turbine or generator or as a result of turbine movement
on the pedestal. Moving a generator may become a problem if too many shims are
used under the generator and it develops a soft foot. As a general rule, don't put
more than three shims under a machine. When you start to exceed this number,
make one thick shim to replace the others. Some longer generators have a support
foot in the center of the span. It is important that this foot is also properly shimmed
when the generator is moved because failing to do this has caused bows in
generators.

REV C 129279
Page 14 Applied Diagnostics

Figure 11. Generator Mounting

8. Generator Cooling

Generators are either hydrogen cooled, air cooled or water cooled. A

combination hydrogen/water cooled system may need to be used in larger units
greater than 500 MW (stator windings may need cooling). Hydrogen is the
preferred cooling medium for most generators because its specific heat capacity
allows the hydrogen to absorb several times more heat than air and its density does
not cause as much windage loss as air does. Hydrogen is explosive when the
concentration drops to 75%; however when the concentration (called purity) is
above this level explosions are not a concern.

REV C 129279
Generators—Basic Design Page 15

Air cooled generators are typically used on smaller capacity units and
combustion turbines that are remotely located. Air cooling has advantages in the
simplicity of the cooling system, the reduced maintenance required and its
suitability to remote operation. Air cooling has a disadvantage in that
contaminants from the ambient air often plug cooling passages and can also form
sufficient deposits to create unbalance within the generator. Typically, the
generator can be cleaned (blown out with compressed air) and the generator can be
returned to service.
Water cooled generators came about as capacity requirements forced
manufacturers to increase the output capability in generator design and still
manufacture a generator that could be transported to the generating station. In a
water cooled generator cooling water is pumped through piping that is built into
the stator. Water has a sufficient specific heat capacity coupled with its low cost
that it makes a good coolant. The cooling water operates in a closed system and is
itself cooled in a water to water heat exchanger. As the water is contained in a
closed cooling system it can be treated to minimize the effects of corrosion and
deposition.

REV C 129279
Page 16 Applied Diagnostics

Malfunction Behavior

Generators and steam turbines have many of the same malfunction

characteristics. The generator rotor system is a shaft supported by a lubricated
bearing at each end. The generator system will have one or two couplings, one of
which is common to the turbine it is attached to. In many ways, the generator is
simpler than the steam turbine, however, the reasons for generator malfunctions are
different and may be more complex.
In this section, we will look at common generator behavior and explore why
malfunctions can occur.

A. Eccentricity (Shaft Bow).

B. Unbalance.
C. Misalignment.
D. Rubs.
E. Fluid-induced Instabilities.
F. Shaft Cracks.

A. Eccentricity (Shaft Bow)

Eccentricity in a generator rotor is also similar to eccentricity in a turbine,

but because generator rotors don't get as hot as a turbine rotor they don't have the
opportunity to sag as much as the turbine rotor does. By the time any bow is rolled
out of the turbine, the bow will be gone from the generator (if it is coupled up), so
generator rotor bows are usually not considered.
REV C 129279
 Generators—Malfunction Behavior Page 17

POINT 4HD ∠45° Right 1X COMP SR: 0∠0° (man) 1.42∠49° POINT 4HD ∠45° Right 1X COMP SR: 0.229∠170° (man) 2.63∠49°
MACHINE: GENERATOR MACHINE: GENERATOR
From: 24APR91 15:56:38 To 16:20:55 Shutdown @ 3819 rpm From: 29APR91 11:28:58 To 30APR91 00:58:59 Shutdown @ 3599 rpm
mil pp mil pp
2.5 2.5

2760
270° 2460 0° 270° 2700 0°
2980
2360 3020
2050 3220
3210
1840 3540
240 2000
990
0 0
3819
1620 3599
1180
1450

180° 90° 180° 90°

2.5 mil pp FULL SCALE CCW ROTATION 2.5 mil pp FULL SCALE CCW ROTATION

Figure 12. Polar response of a Figure 13. Polar response of the

thermally sensitive generator same generator after VARS test
with a shorted turn prior to
conducting a VARS test

Note the change in shape seen in these polar plots!

Generator rotors can develop thermally-induced bows due to electrical

problems within the generator or due to transmission system problems. These
thermally-induced bows happen when differential heating occurs in the rotor. A
test to determine the thermal sensitivity of rotors is the VARS (Voltage Ampere
Reactive) test. For a complete description of a VARS test see Other Diagnostic
Tools, page 33. Under normal circumstances, a generator rotor should have a
uniform current distribution and, therefore, should be heated evenly. If a fault
occurs that causes an increased current density in a localized part of the rotor, it
can cause a hot spot and thermally bow the rotor. If one of the coils "shorts," the

REV C 129279
Page 18 Applied Diagnostics

generator can become "thermally sensitive." This means that there is differential
current flow resulting in differential heating in the rotor and it bows due to
differential expansion, thus causing eccentricity and unbalance as is seen in Figures
12 and 13. Transmission system problems (faults) that affect one phase can cause
rotor surface heating, due to the generation of negative sequence currents. If the
fault is severe enough, it can cause a coil to become loose. Transmission system
faults can also cause more serious damage to the generator. Anytime a generator
vibration problem is being diagnosed, be sure to find out if there have been any
significant transmission system faults that could have caused the observed
behavior. Finally, the generator can be affected by a customer if his load is large
and/or cycles rapidly enough (e.g. supplying power to a steel plant using an electric
arc furnace). If the load is great enough, this can affect the generator, sometimes
promoting a premature failure of the rotor.
Another common cause of generator rotor bows is a result of wedges or
turns sticking in the slots. As a rotor expands or contracts axially, the wedges
should slide along the slot with the rotor iron. If any wedges stick in the slots as
the rotor either expands or contracts, the axial growth/shrinkage of the rotor will be
impeded and the rotor will bow as a result.

B. Unbalance

Unbalance in a generator can be caused by either of two types of forces,

mechanical or electrical. Mechanical unbalance forces are identical to those
mechanical unbalance forces present in a steam turbine, the difference is the
hardware that causes these forces. About the only pieces that can come off a
REV C 129279
Generators—Malfunction Behavior Page 19

generator rotor and cause unbalance are cooling fan blades, balance weights, axial
lead parts and coupling bolts/nuts. If any of these parts come off, there will be a
1X component generated immediately and there will probably be a corresponding
phase shift. Loose parts in a generator can cause a short circuit or possibly an open
circuit; either case would be detectable by the generators instrumentation. Any
loose metal part in a generator will be heated inductively (by the magnetic field)
and, if this part is improperly located will damage the insulation. The important
point here is that serious defects in a generator may be detectable in normal plant
instrumentation that is not part of the vibration monitoring system.
Generator rotors also have parts that can shift and create an unbalance
condition. Generator rotors are an assembly of windings, blocking, insulation
cooling passages and wedges. Turbine rotors have lots of blades that are solidly
attached to the rotor. Windings can't easily be as solidly attached to the rotor;
therefore, it is possible to have a coil move in the generator rotor. A field coil is so
massive it doesn't have to move far to cause an unbalance. The design and
construction of a typical generator rotor can allow a loose coil to slip back into
place when the unit goes on turning gear. This causes the startup and shutdown
data to be markedly different.
Another possible cause of mechanical unbalance comes from a loose or
cracked retaining ring. Retaining rings are usually the most highly stressed
component on the entire turbine/generator. This is not a common problem but has
been seen, especially with some stainless steel alloy retaining rings that are
susceptible to stress corrosion cracking. If the retaining ring is loose and moves,
you will see an unbalance response that is changing. More importantly, any time
the retaining ring does not contact the rotor firmly, there is likely to be arcing
REV C 129279
Page 20 Applied Diagnostics

underneath the ring. Arcing and the related damage would likely produce unusual
field currents and voltages. This is likely to be seen on the normal generator
instrumentation. As some retaining ring designs have the ring electrically
connected to the rotor windings, a loose ring can cause a disturbance in the current
flow within the rotor, causing hot spots and thermal bowing.

Generator

Figure 14. Rotor Bowing due to Differential Heating

Electrically-induced unbalance is also possible in a generator. Inside the

generator are large magnetic fields. Any unbalance in these magnetic fields can
cause or can be associated with "Electrical" or "Thermal" vectors. Electrical and
thermal vectors result in a change in the generator rotors 1X vibration and phase
angle. The change in amplitude and phase angle are a result of the rotor bowing,
due to magnetic or thermal influences. Electrical vectors are usually caused by an
unbalance in the rotor's magnetic field that causes the rotor to be pulled more to
one side than the other and pulls the rotor into a bowed condition. Electrical
vectors can be determined by watching the 1X amplitude when the generator is
excited. If the 1X amplitude and phase changes when the field is excited, it is
responding to electrical forces and the magnitude and direction of the change is the
electrical vector. Further, any two pole generator is likely to show 2X vibration on
REV C 129279
Generators—Malfunction Behavior Page 21

the stator because, as each pole passes a point on the stator, that point is drawn
toward the pole. As there are two poles passing any given point for each
revolution of the rotor, a 2X vibration is created. When the rotor magnetic field is
disturbed, the field's effect on the stator is changed and, therefore, the 2X activity
is changed.
Thermal vectors result primarily due to the rotor bowing because of
localized heating caused by "shorts" or negative sequence currents flowing on the
surface of rotor body. Rotors also bow due to wedges sticking in their slots as was
mentioned earlier. The bowing caused by sticking wedges can correct itself, if and
when, the wedges break free. It is important to remember that, when a rotor bows,
there will always be a change in the vibration and phase angle unless vibration is
measured at a node and unless the direction of bow corresponds to the normal 1X
phase angle. This being the case, it is easy to see the value of monitoring 1X
vibration amplitude and phase angle changes. Also, it is necessary to know the
effects of any electrical or thermal vectors when a balance correction is required on
the machine.

C. Misalignment

Most of what has been said for turbines relating to misalignment also applies
to generators as far as the effects are concerned. Generators are put together with
different hardware, so the root causes are different. The differences arise mostly in
the areas of the feet and the bearing supports.
Generators can be moved to correct a shaft alignment problem. This
movement can cause problems if they are not correctly shimmed or bolted down.
REV C 129279
Page 22 Applied Diagnostics

Generator bearings are usually the same design as those used on the turbine;
however, the bearing supports are different. Typical generator bearing supports are
integral with, or built into, the lower half of the generator endbells. This creates a
support that is more rigid and less prone to movements due to outside forces. On
the downside, any time the lower half of the generator endbells are removed then
the whole bearing system is moved. If the end bells are properly repositioned, this
is not a problem, usually there are alignment dowels and fits to facilitate this, so
there isn't a problem. Keep in mind, however, that the generator endbells are a
variable that is not present in most other machines. Generators with electrical
faults can become thermally sensitive. Besides causing vibration problems
directly, this can also cause differential heating of the generator and change the
alignment.

Soft Foot SHIMS

Motion

Figure 15. Too many shims can act like a spring

REV C 129279
Generators—Malfunction Behavior Page 23

D. Rubs

There is very little in a generator that can rub. The rotor could rub on the
stator, the blower could rub on the shroud, or the seals could rub on the shaft. The
case of the rotor rubbing on the stator is almost impossible because of the amount
of air gap normally found between the two. If the rotor position were to move
enough for the rotor to rub on the stator, there should be other noticeable effects,
such as drastic shaft centerline movement. Rotor air gap is usually checked each
time a generator is inspected and is usually corrected if found to be out of
specification. The most likely cause of a rotor-stator rub is the result of the rotor
being bowed.
However, if a rotor were to be bowed enough to rub the stator, the
synchronous vibration amplitude would have to be much higher than normal and
would not likely go unnoticed.
Hydrogen Side Gland Seal
Air Side Gland Seal
Gland Seal Float Oil
Gland Seal Rings Labyrinth Seal Rings

Bearing

SHAFT

Air Side

Hydrogen Side
Air Side Seal
Oil Drain Hydrogen Side
Seal Oil Drain

Figure 16. Generator Hydrogen Seal and Bearing

REV C 129279
Page 24 Applied Diagnostics

The case of the blower rubbing on the shroud is not usually seen in the
machine’s vibration response. Usually, the internal shrouding is light enough in its
construction to make a hard rub impossible. That is, with a normal shroud there
could not be enough force transmitted to the rotor to make this rub detectable.
Most shrouds are non-metallic and some have been known to disintegrate with the
broken shroud pieces being carried into the generator. Usually, the fan or blower
blades are strong enough to endure such an occurrence without breaking. If a
blower or fan blade were to break or come loose (for whatever reason), the
generator could sustain serious damage. The immediate result of this phenomena
would be unbalance that would be easily detectable. It is also very likely that the
loose blade would damage windings and insulation to the point where the damage
would be seen in the electrical characteristics of the generator. If there were the
serious damage done to the generator that one would expect in this case, you would
expect the generator primary protection relay or one of the other protection relays
to actuate. Protection relays of the type usually used are so fast that the increased
vibration may not be seen unless shutdown data is recorded and analyzed.
The most common type of rub that a generator experiences is a hydrogen
seal rub. When an oil seal or a hydrogen seal rubs on the shaft, it causes the
stiffness of the system to increase, causing the resonant frequency to increase.
This case is just like a turbine seal rub as far as the rotor response characteristics.
The big difference between a generator hydrogen seal and a turbine steam seal is
that the generator hydrogen seals are always lubricated with oil. A rubbing
generator hydrogen or oil seal will usually cause the vibration level and phase
angle to change. Trending the generator's resonance response, and 1X amplitude
and phase is generally the best indicator of a rub.
REV C 129279
Generators—Malfunction Behavior Page 25

E. Fluid-Induced Instabilities

The fluid-induced instabilities experienced by generators are similar to

those experienced by the turbine (there is no steam in a generator, so steam
induced instabilities don't occur). The character of these instabilities are the same
and they look the same on an oscilloscope. Fluid-induced instabilities seen on a
generator rotor have the same root causes.

F. Shaft Cracks

Generators are slightly different than turbines when it comes to shaft cracks.
Generator rotors are not subject to the thermal cycling extremes that a turbine rotor
is. Most generator rotors are one piece, however, there are multiple piece
generator rotors in service. Any rotor, generator or otherwise, will crack if
subjected to a sufficient number of cycles of stress at an appropriate level.
Generator rotors also have been seen to crack in the area of the cooling air holes.
The cooling air holes cause a stress concentration and can lead to crack formation.

REV C 129279
Page 26 Applied Diagnostics

Process Effects

The plant processes don't affect the generator in the normal sense. Steam
conditions, purity and chemistry don't affect the generator at all. As long as the
shaft is turning at rated speed, the lube oil is flowing, the cooling system is
working and the voltage regulator is functioning properly, the generator will
probably be operating within specifications. Occasionally, uneven heating of the
turbine/generator or their pedestals has been the cause of misalignment between
the turbine and the generator. However, the transmission system that the generator
is connected to is where process effects will cause the most problems.
The transmission side of the generator is where most problems will arise, but
there are a number of things that you should know about generators, so you can
figure out what is causing the behavior you are trying to diagnose.
Generators are designed and built to produce rated KVA (Kilovolt Amperes)
output at a specified voltage. The voltage regulator (in automatic mode) will
change the field voltage and current, so that the generators output meets the rated
conditions. If the system voltage is low, or there is a phase imbalance, or the
system frequency is low, or there is a winding fault or suddenly the system goes
very reactive, the voltage regulator is still going to try to bring the generator output
to design setpoint, providing there are no automatic limits. When this happens, the
field voltage and or current may go way out of design limit and start heating the
rotor unevenly, or overheat some wedges, cause some arcing between the wedges
and the rotor body, or generate a higher than normal flux density, and/or do the
same/similar things to the stator. All of this translates to heating of the rotor that
can cause the rotor to bow and thus vibrate. The fore-mentioned conditions, if
REV C 129279
Generators—Process Effects Page 27

allowed to occur over time, can cause permanent damage to the rotor, which may
manifest itself as unbalance. Any of the above malfunctions, along with age and
normal wear, can reduce the insulation's effectiveness to the point where at high
loads or field currents the rotor will bow because of current leakage, causing
localized hot spots. When you hear of a rotor being load or thermally sensitive it's
probably because hot spots are being formed that are causing the rotor to bow.
The meters found on the generator panel and the vibration monitors will give
you valuable information regarding generator behavior. Everything you can learn
about the machine (any machine) will help you understand why it is behaving the
way it is. A good source of information about a generator can be found in the
operating manual that came with the generator.

REV C 129279
Page 28 Applied Diagnostics

Mechanical Effects in Generators

By virtue of their design, generators are not affected much by the

mechanical influences of the plant itself. The effects that are seen come in two
basic categories, effects from misalignment and effects from the exciter.

A. Misalignment

What moved - What should I move?

Generator
L.P.
H.P I.P.

Figure 18. Misalignment. What Moved? What Should be Moved?

Misalignment is a problem that can be seen in any machine and is one of the
most common causes of machine problems. Generators can be misaligned in
basically two ways. The first way occurs when the bearings are not where they
should be. In a generator, this can happen if they are not correctly installed, are not
REV C 129279
Generators—Mechanical Effects Page 29

set at the correct height, fail to swivel (in the case of a spherical cradled bearing) or
are not in the correct location because the endbells that they are mounted in are
improperly (re)placed. When any of these conditions are present, the air gap in the
generator will be incorrect or the alignment between the generator and the turbine
or exciter will be incorrect.
The second way that misalignment is seen in a generator is when the
generator has moved from where it should be, or the turbine has moved from
where it should be. Keep in mind that misalignment means that something is not
lining up properly with something else. Saying that the generator is misaligned is
not really correct. If you're not careful, you can lock yourself into thinking only
about the generator and not about the machine at the other side of the coupling. If
the generator is the machine that moved, it can only move in a limited number of
ways. First, the pedestal can move, it can settle, crack and fail, the earth under the
pedestal can move or wash away or it can be heated or cooled faster than the other
machine pedestals. Second, the sole plates that the generator is bolted to can come
loose from the pedestal, so the generator does not have a solid place to sit. This
could be from a failure of the metal anchors that hold the sole plate down or from a
failure of the grout underneath the sole plate. Third, the problem could come from
improper shimming. This can be a real problem with generators because they are
not usually raised up far enough to get a good look at what is under them. It is not
uncommon to have shims under the feet that don't come out readily and are not
easily seen. The only cure for this problem is to be extra careful when aligning a
generator to be sure that you have removed all the shims and you know exactly
what is under there.

REV C 129279
Page 30 Applied Diagnostics

Exciter Effects

Exciters are the other machine that commonly affects generators. Exciters
supply the generator rotor (field) with the dc power needed to generate the
magnetic field. When you look at how the typical exciter is attached to the
generator, it is easy to see why problems occur there. Exciters are typically
attached to the generator shaft by a coupling that is bolted into the end of the
generator shaft. Commonly after this coupling is made up, a "swing check" is
performed to see that the exciter shaft runs concentric with the generator shaft.
Adjustments to correct exciter misalignment are often made by tightening bolts on
one side of the coupling in order to pull the shaft over in that direction. This
implies that this is not exactly a rigid coupling and, as such, can lead to problems.
In some exciters, there is only one exciter bearing, so the exciter is overhung. Due
to the exciter coupling and the fact that the exciter may be overhung, any
unbalance in the exciter can allow it to vibrate a great deal.
When the exciter is vibrating, it will usually cause high shaft vibration in the
exciter end of the generator. The generator vibration caused by the exciter usually
seems too great to be caused by something outside the generator and can easily
fool you. When the generator is vibrating at the exciter end, the exciter will often
vibrate more than the generator. This is like a "snap the whip" phenomena where
the exciter is at the tail end. Because the two machines are related in this way, it
can be difficult to determine which is causing the vibration.

REV C 129279
Generators—Mechanical Effects Page 31

Figure 19. Brushless Exciter

POINT 4HD ∠45° Right 1X COMP SR: 0.126∠168° (man) 4.82∠40°
MACHINE: GENERATOR
From: 21MAY91 14:42:54 To 22MAY91 14:07:38 Steady State @ 3599 rpm
mil pp
5.0

270° 0°

65 MW / 0 MVAR

0
65 MW / 40 MVAR

180° 90°

5.0 mil pp FULL SCALE CCW ROTATION

Figure 20. Polar plot showing changes as VARS are increased

REV C 129279
Page 32 Applied Diagnostics

Generator / Exciter Diagnostics

How can you tell an exciter problem from a generator problem? First, keep
in mind the generator instrumentation available and what it can tell you. If there is
nothing immediately pointing to the generator, you will need to look a little further.
Generators are more likely to be thermally sensitive than exciters. This means that
you can change load or VARS (Volt-Amperes Reactive) and see if the vibration
amplitude and phase angle changes. If they do change, then the problem is
probably in the generator.
If your exciter has brushes check to see if the bushes are bouncing or arcing
more than they should. If the slip rings are not smooth or concentric, this can
cause vibration. Check to see that all the brushes are carrying about the same load.
If some brushes are overloaded, this can cause arcing which will rough up the slip
rings and cause vibration. If you have an infrared temperature scanning device,
you can look at the brushes to see if some are significantly hotter than others.
Check the exciter air cooling piping to see if it is bound or pulling the exciter out
of alignment. Check the exciter foundation area for any signs of mechanical
distress. Exciters are not as solid as the generator and are more easily moved.
Trend the vibration over time and see what (if anything) correlates to the vibration
change. What is the phase angle doing; is it steady? How did the vibration change
manifest itself, was it sudden or gradual? By relating the change of vibration to
changes in process/load/time, you can probably discover the root cause of the
problem.

REV C 129279
Generators—Diagnostic Methodology Page 33

Diagnostic Methodology Applied to Generators

The diagnostic methodology introduced at the start of this course and later
demonstrated in the steam turbine section is just as necessary when diagnosing a
generator problem, maybe more so. More so because generators have inherited a
mystique that only generator specialists know anything about them. While there is
generally less experience related to overhauling and repairing generators than any
other piece of equipment in the plant, it is not true that you can't figure out what is
wrong with a generator. To conduct an effective diagnosis on a generator, proceed
as with any other piece of equipment. Start with the diagnostic methodology and
work your way through the list. What is the problem? What do I already know?
What does this tell me? Do I need additional data to prove my diagnosis? Does
the analysis fit the symptom for the machine I'm looking at? These are all the same
questions as before. If you start at the beginning and work your way through, you
can figure out what is happening. For example, you know that the generator is
vibrating because you have good equipment and you know that it is working
properly. You know, or can find out, when the vibration started or first became
noticeable. You can find out if there is some load sensitivity demonstrated. You
can check the electrical parameters. Maybe you can do some load or VAR
changing and measure the response. As long as you stick to a diagnostic
methodology and work methodically, you have a good chance of determining the
cause of the problem. Even if you don't figure out what is wrong, you will have
checked enough of the important parameters with enough detail that if you do call
for outside help you will be able to answer their questions. If plant personnel are
heading off in the wrong direction you will be able to recognize that as well.
REV C 129279
Page 34 Applied Diagnostics

When you are diagnosing a machine that you are not very familiar with, using a
diagnostic methodology can be easier than with a familiar machine. That is
because when diagnosing a familiar piece of equipment you know the equipment
so well that you are more likely to move to the next step without thinking carefully
about all the information you have. A new piece of equipment forces you to think
about every step carefully, so you are less likely to deceive yourself or be misled
by what you think you know.

REV C 129279
Generators—Information Required Page 35

Information Required

When diagnosing a problem in a generator, the information needed will be

somewhat different than the information required for a steam turbine because a
generator is primarily an electrical device. The minimum vibration information
required is overall amplitude, 1X and 2X amplitude and phase and steady state
shaft position (D.C. Gap). Bearing metal temperature and lube oil supply and or
drain temperature will also be needed. Generators are usually well-instrumented,
so the following listed information will usually be available on the generator panel.
By studying the electrical and mechanical vibration information coming from a
generator, the root cause of the problem can be isolated as either an electrical or
mechanical problem. The trend information needed to perform effective analysis
is:
Rotor vibration and position measurements.
Bearing metal and lube oil drain temperatures.
Load
VARS
Output Voltage
Output Current
Individual Phase Current
Individual Phase voltage
Excitation Voltage/ Field Voltage
Excitation Current/ Field Current
System Frequency
Hydrogen Gas Pressure/ or cooling water temperature.
REV C 129279
Page 36 Applied Diagnostics

These readings can indicate the condition of the generator mechanically and
electrically. Check to see if these meter readings are within the range that they
normally should be. If your generator has imbedded stator temperature
thermocouples check these readings to see if they are where they should be. Next,
check the seal oil system (where present) and see that the seal oil pressure is
correct. Check to see that the seal oil temperature and pressure is correct, as
hydrogen seals can be the source of a fluid-induced instability. Finally, check to
see if your instrumentation agrees with your system control readings because it is
possible that your instrumentation is faulty and causing the regulator to over or
under-excite the generator.

Figure 21. Typical Generator Panel Instrumentation

REV C 129279
Generators—Other Diagnostic Tools Page 37

Other Diagnostic Tools

Whenever you are diagnosing a problem in a generator, it is always a good

idea to look at the generator panel meters and see if all the readings are where they
should be. Generator vibration can be caused either mechanically or electrically,
so you really need to look at the meters to determine which type of problem you
have. Also, you should know what the indications should be and what they
normally are for the present load conditions. Typically, there is enough generator
instrumentation in a power plant to determine if you have an electrical problem, so
by all means use it!
In a typical power plant, you can count on seeing the following meters on
the generator panel:

Individual phase current

Individual phase voltage
Excitation voltage / field voltage
Excitation current / field current
Generator VARS
Output voltage
Output current
Megawatt load
System frequency.

By just looking at these meters a person can get a pretty good idea if there is
electrical trouble in your generator or system.
REV C 129279
Page 38 Applied Diagnostics

A. Diagnostics of a Generator

Starting with individual phase current and voltage meters, whatever the
reading is, it should not differ from meter to meter by more than a few percent.
The higher the unit load, the less difference there should be. Talk to the control
room operator and look at the log sheets to find out what is normal. Whenever one
phase voltage or current is different from the other phases, one or more of the
individual phases will be more heavily loaded than the other(s) and could be
dangerously out of tolerance. In any case, excessive phase imbalance is a sign of
problems. If the phase imbalance occurrence corresponds to the vibration problem
there is a good chance that the two are related.
Look at the exciter voltage and current. Is this where it should be or
normally is? In the case of phase imbalance, there is a good chance that one or
both of these parameters will be out of specification for the present load as well.
Check the generator output voltage and system frequency. Remember that
the voltage regulator will excite the field as required to make the required KVA
and can overexcite the field. If the system voltage or frequency is too far off
design and your regulator is in auto, you could be damaging the rotor and or stator.
Under frequency operation means that the rotor is turning slower than it should
and may not be cooling properly.

REV C 129279
Generators—Other Diagnostic Tools Page 39

Check the VAR meter: the more VARs, the lower the allowable output of
the generator. Compare the load and VARs against the reactive capability curve,
are you exceeding the allowable rating? An important caution here is that most of
the panel meters are fed from PT's (potential transformers) and CT's (current
transformers), so before you start tearing the generator apart make sure that these
are operating correctly.
When a generator's vibration response changes markedly to a change in
VARS there is a possibility that the generator rotor has a shorted turn. VAR tests
are a common way to determine if a rotor has a shorted turn. The theory behind a
VAR test is that when VAR loading is increased the current in the field will also be
increased. Any short circuit within the field will cause increased heating and will
cause the field (rotor) to bow. The bowing can be easily seen in a polar plot, see
Figures 12,13 & 20.
To conduct a VAR test the VAR output is increased to near the limit
specified in the generator's reactive capability curve typically found in the
generator manual. When the VAR output is increased, check for a change in
vibration and phase angle of the generator. Also, monitor the cooling medium
outlet temperature for increases as there is no way to monitor the rotor temperature
directly. Finally, and most importantly, be making a polar plot of the generators
vibration response during the VAR test as this will be a permanent record of the
generators response during the test. The VARS leading or lagging, cooling
medium inlet and outlet temperature and generator load should also be written on
the plot. VAR tests are common and not damaging to the generator when
performed correctly, however; the original equipment manufacturer should be
consulted prior to conducting a VAR test.
REV C 129279
Page 40 Applied Diagnostics

There are a few more indications that can help you that should be looked at.
These are the fluid/gas inlet and outlet temperatures, and, if applicable, hydrogen
purity. It is very important that the generator be cooled evenly and enough so that
there are no hot spots or insulation damage occurring. It is a good idea to know
what the normal cooler differential temperature should be. As far as the hydrogen
purity goes, the purer the hydrogen, the better cooling capacity it has. Further, the
purer the hydrogen, the less heating occurs due to windage.

REV C 129279