before failure by the corona probe tech- of voids and imperfect impregnation of the creasing slightly the gap

lightly the gap length across the

nique.
H. C. Marcroft: The author wishes to
thank the discussers of this paper for the
constructive additional comments and in-
formation which they have given toward the
over-all problem of evaluating the condition
of armature coil insulation by field tests.
This problem of coil evaluation has been ap-
proached from a number of directions in the
past few years so that now the mystery of
the causes of coil failures is yielding to per-
sistent attack by measurements of various
kinds.
In reply to the comments of Mr. Cameron,
with respect to length of time used for
charging the insulation on the absorption
runs, our practice has been to terminate
these runs at 10 minutes' time. Theoret-
ically, the current decreases to infinite
time and a practical limit of 10 minutes was
set some years ago with the establishment
of the Polarization Index indicator which
is the ratio of resistance at 10 minutes' time
to that at 1-minute time. Polarization In-
dex was one of the quantities of this machine
we wished to investigate, so the established
procedure was retained. Investigation of
the effect of longer charging times will be
made on future tests if possible. Data for
specific absorption were obtained during the
runs, though they do not appear in the
paper.
The current fluctuations on d-c tests were
caused by the subject insulation under test,
as careful observance was made of the a-c
supply voltage which was supplied to the
rectifier test set through a constant voltage
transformer. Other tests were free of dis-
turbances for the same supply conditions.
Mr. Cameron has shown in a paper' that
the ionization probe test has revealed serious
destruction of copper conductors of a coil;
however, no such destruction was found in
any of the coils of the machines subject to
our tests, though there was a good amount
coils of the old machines B and C. No cor-
responding probe tests were made. Because
of the low working voltage of the coil failing
in machine E, the evidence is good that
mechanical forces were the cause of coil
failure. Internal corona damage was non-
existent on adjacent coils. The ionization
probe tester apparently is quite reliable in
detecting (where it can be used) voids be-
tween conductors and iron, but it will not
detect necessarily the approaching contact
of two conductors within a coil where there
is no void between conductor and iron to
cause ionization. It was for this reason that
direct measurement of turn-to-turn strength
was used.
C. M. Foust has shown by the data he pre-
sents from tests made years ago on a ma-
chine of similar coil insulation that substan-
tial agreement with our tests was obtained
with respect to the d-c toa-c breakdown ratio.
His Table I of this ratio for various wave
shapes of applied potential is of particular
interest in demonstrating that steady d-c
potentials will break down old coil insulation
at approximately the same value as com-
mercial a-c peak value.
Mr. Foust raises the question of the in-
dividual turns of a multiturn coil sustaining
equal shares of the applied high-frequency
potential from the circuit used for the turn-
to-turn tests. Theory and practice gener-
ally indicate that the outside turns are sub-
ject to greater voltages on steep waves. This
question was studied by connecting an os-
cilloscope across separate turns of a simu-
lated coil under test for visual study. The
magnitudes were very unsteady so that this
method proved to be unsatisfactory. In-
dividual spark gaps then were attached to
each turn of a 4-turn coil, all set at equal
gaps. The coil was energized from the high-
frequency circuit of Figure 3 of the paper,
noting, on many applications, which gap
sparked over first. The conclusion was that
one of the inside turn gaps sparked over
first as often as the outside gaps did. In-
outside turns resulted in only the inside
gaps sparking over. While this determina-
tion of the linearity of turn voltages may
lack precision, it is believed that the method
of stressing the turn insulation as described
using the circuit of Figure 3 is a reasonably
close approach to uniform application of
turn potential.
The test circuit is operated without any
connected grounds in the coil circuit. The
coil in the core is effectively at low potential
at the high frequencies because of coil capac-
itance. It was believed that an additional
ground would destroy the coil balance to
ground.
E. H. Povey presents conclusions sup-
porting the statement that d-c high poten-
tial tests are not always nondestructive.
The art will benefit from the experience of
others contributing evidence to show the
behavior of generator insulation under high
direct potentials.
The possibility of detecting the impending
failures of the coils in generators A and D
by corona probe detector is raised by MIr.
Povey. This test was not applied to any of
the generators, so we can not say what the
results of such tests might have been. How-
ever, judging from the general absence of
voids in the ground insulation of machines
A and D, it is believed that little definite
corona indication would have been obtained.
There was definitely no visible corona dam-
age inside the ground insulation of similar
coils. The insufficient turn spacing and turn
insulation thickness could easily account for
the failure of generator A, as was shown on
the turn breakdown tests. The failure of
generators D and E soon after starting gives
us a clue that thermal cycles were a con-
tributing factor to the turn failures of the
coils involved. It would seem to be sound
procedure to make both the corona probe
tests and turn dielectric tests where possible.
REFERENCE
1. See reference 1 of the paper.

New Large Short-Circuit Testing Generator Requirements

Generators
C. E. KILBOURNE
FELLOW AIEE
THE phenomenal growth and exten-
are short-circuit generators in which are
sive interconnection of American created the voltages and currents used
power systems has made necessary ex- either directly or through transformers, to
panded testing facilities for the develop- provide the conditions necessary for
ment of large circuit interruptors. As- switchgear testing. A number of such
sociated with this growth, the continual generators have been built in this country
search for knowledge of the various factors and abroad, and this paper describes two
influencing the design of switchgear de- new additions to the family. These ma-
vices has emphasized the need for many chines were put in service at the Philadel-
refinements in previously existing testing phia Switchgear Testing Laboratory of the
equipments. Among the essential com- General Electric Company during the
ponents of a switchgear testing laboratory past winter.
Short-circuit testing generators differ
from all other generators in several re-
spects. They operate for very brief
periods of time, usually of the order of
Paper 52-221, recommended by the AIEE Rotating
Machinery Committee and approved by the AIEE
Technical Program Committee for presentation at
the AIEE Summer General Meeting, Minneapolis,
Minn., June 23-27, 1952. Manuscript submitted
March 24, 1952; made available for printing May
13, 1952.
C. E. KILBOURNE is with the General Electric Com-
pany, Schenectady, N. Y.
The author wishes to acknowledge the fine work of
many of his associates in the General Electric Com-
pany who contributed so ably to the solution of the
problems involved in the design and construction of
these machines, thus making this paper possible.
He is particularly indebted to G. B. Warren, E. E.
Parker, H. D. Taylor, M. F. Kent, R. Patterson,
D. B. Harrington, D. M. Willyoung, W. L. Dor-
mandy, W. Scidmore, J. P. Keller, L. E. Newman,
A. Martinson, A. J. Hart, now or formerly of the
Turbine Division, and to P. L. Alger, Consulting
Engineer, and R L. Williams, Switchgear Depart-
ment, without whose support and encouragement
this project could not have been accomplished.

OCTOIBER 1 952 Kilbourne-New Large Short- Circuit Testing Generators sc9


cycles, at extremely high kilovolt-ampere
values and under the most severe me-
chanical forces and stresses. Then they
have relatively long rest periods when
they are required to perform only moder-
ate service, such as the generation of
voltage, and even longer periods when
they perform no electrical service. The
complete design of these machines is in-
fluenced by these requirements, stressing
the ability to produce large short-circuit
currents, with mechanical design to with-
stand the associated forces, and minimhiz-
ing the continuous load carrying ability.
Like a cannon they speak with great force
when used, then remain quiescent until
called upon once again.
Figure 1 is a station view of the first
of these machines to be put in service at
the Philadelphia switchgear testing labo-
ratory of the General Electric Company
during the past winter.
The physical size of these generators, as
compared with commercial generators, is
best indicated by the assignment of a
nominal rating of 125,000 kva, 4 poles,
1,800 rpm, 60 cycles. Each generator will
deliver, 1/4 cycle after the application of a
3-phase short circuit at its terminals, at
least 1,625,000 kva symmetrical when
initially excited to an open circuit voltage
of 15,500 volts. On this same basis, the
two generators connected in parallel will
deliver 3,200,000 kva at the several test
cells in the laboratory. At this rating,
they are believed to be the largest such
units presently in operation.
In addition to their size they possess a
range of operation and a flexibility in
their duty cycle which makes them quite
versatile. They are driven by 3,000-
horsepower wound rotor induction motors
equipped with slip regulators, which are
capable of driving the generators at any
frequency from very low values up to 60
830 Kilbourne-New Large Short-Circuit Testing Generators
Figure 1. One of
two 1 ,625,000-sym-
metrical short-circuit
kilovolt-ampere test-
ing generators at the
Philadelphia Switch-
gear Testing Labora-
S ~~~tory
cycles. The generators may be short-
circuited in the general range of 8 to 12
cycles when simulating current build-up
for testing d-c equiipment, and for a-c tests
may be short-circuited at any frequency
between 25 and 60 cycles. Wvhen operat-
ing at less than 60 cycles they will deliver
essentially constant short-circuit current
at initial voltages proportional to the
speed. Their armnature windings have
two circuits, brought out to separate ter-
minals so that, with Y and delta connec-
tions, a choice of four 3-phase voltages, at
60 cycles 15,500/7,750 volts Y or 8,950/-
4,475 volts delta, can be obtained. Also,
any of the 3-phase connections may be
operated single phase with one terminal
grounded, which on the 15.5-kv connec-
tion, necessitated insulating these wind-
ings for an equivalent 3-phase voltage of
26.5 kv.
The duty cycle required, together with
a very low decrement rate of the short-
circuit current characteristics, were im-
portant factors in determining the phys-
ical size of the units. The machines are
capable of 15 3-phase or single-phase 5-
cycle full-power short circuits per hour.
These 15 short circuits constitute 3 duty
cycles, each one of which consists of 5
short circuits at intervals of 0.2, 15, 30,
and 60 seconds between short circuits.
Full field excitation is needed during these
cycles and for preparation prior to the
cycles, making a total time of full excita-
tion about 15 minutes out of an hour. In
addition, a reduced value of field excita-
tion is required for a 4-hour period to sup-
ply exciting current to the transformers.
As well as perforning their electrical
duties, the maebines were required to be
good neighbors in a possible future resi-
dential area. Since short-circuit opera-
tion is productive of heavy ground shocks
and large high-speed rotors produce wind-
age noises, novel features were introduced
in the mechanical design of these sets to
minimize these objectionable features.
Electrical Design
Two major electrical requirements
dominated the design. The first, the large
current to be handled is obvious from the
rating. At 1,625,000 kva rms symmet-
rical at 15,500 volts the machine current
is 60,500 amperes rms, and when one
takes into account the magnitude of the
instantaneous values of fully offset cur-
rents, the current in the individual bars
of the winding under some conditions of
excitation can be over 100,000 amperes.
Such currents create very large magnetic
forces and the electrical design had to be
adapted to mechanical construction which
would support these forces. The second
requirement was that these high currents
be sustained at as nearly their initial
values as possible over the 5-cycle short-
circuit period. A very long time constant
together with a low resistance, particu-
larly in the rotor circuits, seemed to be the
way to meet this situation.
Because of these things, these gener-
ators differ considerably from the elec-
trical proportions of conventional ma-
chines. The armature slots are relatively
few in number, are quite wide, and are
only about 60 per cent of normal depth.
Their copper cross section is less than
that found in other machines as the rms
ARMATURE CURRENT ENVELOPE
FULL VOLTAGE, 3 PHASE, 60 CYCLE TERMINAL SHORT CIRCUIT
16 __ _ =
w
0
00
n
--
a ___
e
2'... + ;t
3
z
CI
rIM2 IN CYCLES
Figure 2. Calculated and test envelopes of
symmetrical 3-phase short-circuit armature
current
Curve A-Calculated
Curve B-Test results, corrected for bus re-
actance
OCTOBER 1952
heating cycle is small. All of these factors
contribute to low armature reactance and
hence high currents. For mechanical
support of the armature end windings, the
extensions of the coils beyond the core
were made cylindrical, instead of in the
usual flared back conical arrangement,
and this arrangement contributed to
short end extensions which were of help
both in simplifying the supporting prob-
lems and in contributing to low reactance.
The flux densities in the armature are
somewhat higher than normal. Their
maximum values, however, are limited be-
cause of the requirement that the gener-
ators provide excitation to the transform-
ers for a 4-hour period. Also extensive A
studies of the effect of saturation on the Figure 3(A). Three-phase 60-cycle 1 5,500-volt short circuit
short-circuit current decrements indi-
cated that while saturation is beneficial in Trace A-generator volts, lines 1, 2, 3
obtaining large currents for the first 1 or Traces B, C, D-generator current, lines 1, 2, 3
2 cycles, it tends to hasten the decay of Traces E, Eo-generator field current and reference
these currents and, therefore, acts in a The first current peak of curve B shows 182,000 amperes instantdneous current
manner unfavorable to sustaining the
initial current values.
The rotors are equipped with heavy
low-resistance amortisseur windings which
provide paths for the flow of the large
currents that are necessary to meet the
rotor magnetomotive force requirements
whlen the arnratures are short-circuited.
The excitation windings are, like the arm-
ature windings, reduced in copper cross
section, as their heating duty is lower
than normal. However, the transformer
excitation requirement again prevented
taking the full advantage of this reduction
which would otherwise have been pos-
sible.
Figure 2 shows the calculated and test
envelopes of the full voltage 3-phase sym-
metrical armature current characteristic, B
and Figure 3 shows two oscillograms, one Figure 3(B). Single-phase 60-cycle 1 5,500-volt short circuit, completely offset current wave
of a full voltage (15,500 volts) 3-phase
short circuit which is nearly symmetrical Trace A-generator volts, lines 1, 2, 3
in one phase, and the other of a com- Trace B-generdtor current, line 3
pletely offset single-phase short circuit. Traces C, Co-generator field current and reference
The first current peak of curve B, Figure
3(A), shows a current of 182,000 amperes,
which is believed to be the largest high- sion into the air gap. When 3-phase short mounting for the end winding supporting
voltage connection current so far gener- circuits are applied, those slots in which structure.
ated in a single short-circuit generator. the bars carry currents flowing in the same The problem of end winding support
direction and reaching their peak values was given much thought and a new
The Stator simultaneously encounter very large method of accomplishing this function de-
forces pushing the bars against the bottom vised. After making a number of tests in
An end view of the unwound armature of the slot and this double wedging serves which large currents were forced through
showing many of the details of construc- to lessen the maximum insulation crush- unsupported sections of bars simulating
tion can be seen in Figure 4. Aside from ing force on the bottom coil side. Also the end windings, it became apparent that
the methods of mounting, which will be independently wedged bars give better to withstand the thousands of short-cir-
discussed later, the details of the slots and support to each bar, lessening the move- cuit shocks to be expected in the life of
part of the end mechanical construction ment of the bars under short-circuit forces this winding, the bars should be com-
can be seen. Each slot has two wedges, as the insulation ages. The heavy clamp- pletely supported throughout their entire
one holding the bottom coil side in the ing ring at the end of the core puts pres- length. The slot portions were already
bottom half of the slot and another hold- sure on the punchings to hold them firmly encased in iron, but new end supporting
ing the top coil side to prevent its expul- in place and also serves as a mechanical structures were required. Because of the

OCTOBER 1952 Kilbourne-New Large Short-Circuit Testing Generators 831


cylindrical shape selected for the coil ex-
tensions, this end supporting structure
could be provided in the form of circular
segments of insulating material slotted in
their inner surfaces with tapered slots
similar to the arrangement of the slots on
half of an internal herringbone gear, and
these slots used to contain the coil end
extension fitted and wedged in place.
Figure 5 is a view of the test setup which
was used to prove the adequacy of the
selected structure. It shows four arcs,
each of a heavy section of an impregnated
laminate, arranged with one pair nesting
in the inner surface of the other. An ex-
amination of the figure will show the slot-
ting arrangement and two pairs of bars,
one pair in the inner set of rings and
one pair in the outer set protruding from
the slots in the structure. During tests
the ends of these bars were firmly braced
832 Kilbourne-New Large Short-Circuit Testing Generators
Figure 4 (left).
End view of un-
wound stator
frame showing
armature core,
Frame, trunnions,
and spring feet
Figure 6 (right).
Outer diameter
layer of end
winding support-
ing structure as-
sembled on the
stator frame
and currents ranging in magnitude from
100,000 to 300,000 amperes per bar re-
peatedly applied to them. The structure
withstood these tests and then higher
currents were applied until the structure
was destroyed.
The application of this development to
the machine end windings is shown in
Figures 6 and 7. The first view shows the
outer rings in place in a split and insu-
lated nonmagnetic steel binding ring
which is free to adjust itself in axial posi-
tion by sliding on keyed supporting
brackets as the windings expand or con-
tract under changes in thermal loading.
The second view shows the outer layer
of windings in place and a partial as-
sembly of the inner layer. The barrel
shape instead of the conventional conical
flare-back of the end windings can be seen.
The two layers of the supporting struc-
Figure S. Test
sembly of end wind-
ing supporting struc-
ture
ture are bolted firmly together and to the
nonmagnetic rings with long tapped bolts.
A good view of the finished end winding
is shown in Figure 8, taken at the Switch-
gear Plant at Philadelphia during installa-
tion. Only the loops and phase connec-
tions which are short solid sections of cop-
per extend beyond the supporting struc-
ture. The circuit rings, as can be seen,
also are solidly blocked and supported by
brackets which fasten firmly to the end
structure of the frame. The stator leads,
also of solid copper cross section, are
brought out at the connection end of the
frame where they are supported by a steel
framework having insulated clamping
members. Slightly below the bottom of
the main frame, the solid copper bus bars
connect to extra flexible cable leads which
in turn lead to the station bus work. The
necessity for these extra flexible connec-
tions between the frame and the stator
bus work will become apparent when the
mechanical movements of the frame are
described.
The Rotor
Two features of the rotor are of par-
ticular interest. The requirements of very
low decrement rates for the armature cur-
rents, and also single-phase testing dic-
tated, as has been said, a very rugged low-
resistance amortisseur winding. In addi-
tion, the rate of deceleration of the rotor
as- during a short circuit is very high be-
cause of the power losses during these
brief periods of time. This rapid change
in speed creates inertia forces tending to
OCTOBER 1952
 Figure 7 (left).
Partial winding
assembly show-
ingo details of the
end blocking ar-
rangement

Figure 9 (right).
End view of the
rotor, retaining
ring removed,
showing amortis-

seur winding
construction

demand. The radial pins shown in the

illustration are temporary dowels and
were removed before assembling the re-
rotate the end portions of the field wind- do double duty as both current carrying taining rings. The amortisseur winding is
ing and the retaining rings with respect members and wedges. Beneath these complete, not only in the normal rotor
to the rest of the rotor body. The prob- sections are also several rectangular cop- slots but also over the pole center. In the
lem of holding these end parts in their per strips, lying in the top of the rotor pole center shown in the figure will be
relative positions on the rotor is some- slots and providing both an addition to noted a rectangular recess with rounded
what augmented by the necessity to use the current-carrying capacity of the corners. The retaining rings each have
nonmagnetic retaining rings for loss and winding, and lowering its resistance. The four lugs which project into these recesses,
reactance reasons, and hence to consider end connecting straps of the winding are and the dowels shown in the picture lock
in the design the relative coefficients of made of sheets of copper, cut into arcs with these lugs, and together with shrink
thermal expansion of the magnetic and and with projecting fingers which extend fits between the retaining ring and the
nonmagnetic parts. into the rotor slots, connecting with the main body, and between the retaining
Figure 9 shows these features. The rectangular bars and completing the ring and the end centering ring, prevent
amortisseur winding in the slot portion is amortisseur circuit. The arcs of the end any possible rotation of the retaining ring
composed of trapezoidal alloy copper bars, winding are free to expand and contract during high rates of acceleration or de-
which in combination with steel wedges, as speed and temperature conditions may celeration of the rotor. At high speeds,

Figure 8 (below). Lowering the stator of the number 1 unit to its final
assembly position in the testing laboratory
Figure 10 (right). Scale model used for predetermining the vibrational
characteristics of the generator spring mounts

OCTOBIER 1 952 Kilbourne-New Large Short- Circuit Testing Generators 83.3


Figure 11. Base and spring mounting assembly in place in the testing laboratory
centrifugal forces lock the remainder of
the end structure to the retaining ring,
and at low speeds heavy blocking in the
field winding end portion holds those
windings against displacement.
The Mounting
The foundation shock of short circuit,
plus the pulsating torques present during
single-phase operation, required a means
of absorption which would minimize these
phenomena. The necessity to operate at
any frequency between 60 and 25 cyeles
indicated a very soft mounting capable of
yielding to circumferential motion of the
frame, and yet able to hold the frame
centerline accurately in space. The very
low frequency used to simulate d-c testing
complicated the problems of design for
a-c testing, and finally a separate solution
for this type of operation had to be found.
The dead weight of the stator which any
spring system must handle is slightly over
400,000 pounds and the maximum torque
under the most severe short circuit is
about 8,000,000 pound feet.
A number of possible spring systems
which would answer this problem were
studied. The conventional helic? spring
assembly so successfully used on single-
frequency isolation problems proved dif-
ficult to apply and obtain both the soft-
ness of mounting and the maintenance of
alignment necessary in this application.
The leaf spring system arranged in axial
distribution under the normal position of
generator feet required so much material
to accomplish the objectives that a very
bulky assembly would have resulted.
Finally a new system was devised.
834 8Kilbourne-New Large Short-Circuit Testing Generators
Figure 10 shows a 1/8-scale model of a
portion of the stator and spring system
which was chosen. The model was exten-
sively tested to determine its vibration
characteristics and finally stressed to de-
struction to determine the maximum
torque it would withstand. Figure 4 as
well as showing details of the armature
core of the big generator also shows the
spring leaves attached to the stator, and
Figure 11 shows a clearer view of these
same spring leaves in place in the base at
Philadelphia. In connection with Figures
4 and 11, it should be noted that the same
spring leaves are shown attached to the
stator and attached to the base in both
figures For shipment the leaves were as-
sembled in the base, and the stator in the
condition shown in Figure 12 was lowered
onto the springs, and the two assemblies
bolted together. Figure 12 is interesting
from another viewpoint in that the stator
shown,loaded on the car, when completely
Figure 12. Com-
pletely wound
stator being placed
on a car
boxed for shipment, had a total weight of
about 420,000 pounds, and at its date of
shipment was the heaviest single piece
ever shipped from the Schenectady Tur-
bine Generator Factory of the General
Electric Company.
The system of 45-degree radial spring
feet possesses very favorable characteris-
tics for this type of application. The
springs are relatively soft to circumferen-
tial rotation of the frame, thus providing
considerable cushioning for short-circuit
operation of all kinds, and yet are very
rigid to gravity deflections. It is interest-
ing to note that when the stator is low-
ered on the feet the dead weight stresses
in the springs permit an initial displace-
ment of only 0.35 mil. Under the most
severe conditions of 25-cycle short circuit,
the stator trunnions, two of which are
shown in Figure 12, move a total distance
of about 11/4 inches and the associated
angular rotation of the frame is about 0.75
degree. During this motion the spring
feet hold the axial centerline of the frame
within 30 mils of its rest position, an en-
tirely negligible motion with the large air
gap present in these machines.
Figure 13 shows two vibrographs of the
motion of the trunnion with respect to the
base under 25-cycle short circuits. Sev-
eral things of interest are apparent in these
records. First, the large movement of the
frame which leads to effective cushioning
of the shocks is combined with a high
damping characteristic which brings the
frame to vibrational rest quickly so that
succeeding shocks will not amplify its dis-
placement. Second, the mounting is
very sensitive to the applied torque and
the presence of second harmonic torques
under single-phase operation is clearly in-
dicated in the shape of the vibrograph
reading on that short circuit. In fact, the
vibrograph readings taken of a number of
short circuits are so consistently related
among themselves in predicting the antic-
OCTOBER 1952

A 0.9 inch
B cation.
ipated relationships between the torques
produced by the short circuits and the
currents that flow under short circuits
that they could be used as rough calibrat-
ing instruments to determine the short-
circuit current.
The trunnions serve a dual purpose.
Not only were they used during manufac-
ture and erection to handle the stator, but
after erection each trunnion is encased in
a trunnion block leaving clearance around
the trunnion to permit the motions indi-
cated previously. The bases of the trun-
nion blocks on one side of the machine can
be seen in Figure 11. After the stator is
in its final position, caps were placed on
top of these blocks to complete the en-
closure. The critical frequency of the
spring feet being somewhat less than half
the lowest a-c operating frequency of 25
cycles makes them too "soft" for opera-
tion at 8 to 12 cycles, and the trunnions
and their supports provide an answer for
this situation. During simulated d-c test-
ing operations the trunnions are solidly
blocked in their supports, thus effectively
removing the springs from the operation
of the unit. Since such operation is at low
frequency the shock waves associated
with it have gradually rising faces and
their effect on foundation shock is not ob-
jectionable.
The Enclosure, Bearings, Driving
Motor, and Other Equipment
The many speeds at which these ma-
chines operate made it virtually impossible
to incorporate adequate self-ventilating
features in their rotors. Consequently,
as is apparent in Figure 1, each unit is en-
closed in a sheet metal covering which
OCTOBE-R 1 952 RKilbourne-New Large Short- Circuit Testing Generators
Figure 13. Rectified
motional vibrographs
of the generator trun-
nions
(A)Three-phase full-
voltage 25-cycle
short circuit. The
total movement indi-
cated by the sum of
the first two peaks is
(B) Single-phase 25-
cycle short circuit
showing harmonics
in the generator
torque wave as re-
corded in stator dis-
placement
serves as a ventilating housing and also as
a mounting for four motor-driven blowers
and two coolers which occupy the top
semicircular portion of the structure.
During iight-load operation two of the
blowers may be shut down to decrease
losses. For sound-deadening purposes all
internal sheet metal surfaces of the hous-
ing are sprayed with a heavy layer of
sound isolating compound.
The bearings for short-circuit genera-
tors are of interest principally for the
problems of shaft current control which
arise due to the nature of the operation of
the units. The familiar problem of in-
sulating the bearings to prevent circulat-
ing currents tending to loop the stator is
augmented by the possibility of small
magnetic unbalances due to the axial
magnetic centering of the rotor at the in-
stant of short circuit, which, should small
magnetic dissymmetries exist, would
cause the shaft to carry axial fluxes as
well as currents through the bearing jour-
nals. Thus it was felt necessary not only
to insulate the pedestal against the flow
of current but also to provide magnetic
insulation by making the bearing shells
of nonmagnetic material. These two
provisions have so far been successful in
preventing bearing pitting.
The driving motor, a 3,000-horsepower
wound rotor induction motorwith slip reg-
ulator control will bring its generator up
to full speed in 10 minutes and will ac-
celerate it to speed promptly after a short
circuit. It is mounted on the end opposite
to that shown in Figure 1. The mostlun-
usual problem in the construction of -this
motor and in combining it with the gener-
ator lay in the mechanical construction of
the motor rotor and in making the cou-
pling between- the motor and generator
rotors to withstand the short-circuit
torques which are transmitted to the induc-
tion motor because of its mechanical in-
ertia. This was similar to the problem
encountered in the generator rotor ends
but was somewhat augmented because of
the amplification possible due to the
transient characteristic of the applied
torques combinedwith the shaft reactions.
When it is realized that the maximum rate
of deceleration due to alternating short-
circuit-torque is in the order of 6,000 rpm
per second, depending upon the type of
short circuit, the size of these inertia
forces present can be appreciated.
Also connected to the main shaft, and
shown in Figure 1, are a pilot generator
for controlling the timing of the circuit
closure and a tachometer for speed indi-
Future Uses of the Features of These
Machines
While most of the novel features of
these machines are of principal interest
for short-circuit generators, a number of
them may find application to more con-
ventional units. The heavy amortisseur
windings incorporated in these rotors
offer a number of interesting possibilities.
Single-phase cylindrical rotor generators
have incorporated some of these features
and they may be applicable to more con-
ventional machines when synchronous
condenser operation is considered or when
round rotor svnchronous condensers are
built.
Furthermore, such windings offer a
means of increasing permissible rotor sur-
face currents that arise during certain
types of system short circuits which occur
to conventional machines. Nonmagnetic
retaining rings, whose advantages have
long been recognized, have here been ap-
plied to very large machines. With fur-
ther development their use may be ex-
tended to other units.
The stator winding end blocking meth-
ods, while admittedly difficult to apply,
nevertheless, have advantages which can
be exploited when proper cooling methods
are used to remove heat from windings
carrying conventional loads. Such a
winding would have great ability to with-
stand short-circuit shocks. The knowl-
edge gained in studying the effects of
saturation on short-circuit characteristics
already is proving of value in the design
of conventional units.
Finally the problems encountered in
the construction of such special units are
of use in expanding the experience and
skill of the same people who construct
835-
much of the power equipment needed for
today's expansion programs.
References
1. THE HIGH CAPACITY CURRENT INTERRUPTING
TESTING STATION OF THE GENERAL ELECTRIC
COMPANY, C. E. Merris. General Electric Review
(Schenectady, N. Y.), volume XXVI, June 1923.
2. OIL CIRCUIT BREAKER INVESTIGATION AS
CARRIED ON WITH A 26,700 KVA GENERATOR,
J. D. Hilliard. AIEE Transactions, volume
XLIII, 1924, pages 641-47.
Discussion
P. L. Alger (General Electric Company,
Schenectady, N. Y.): This generator is
notable for the high sustained value of its
short-circuit current, which is relatively
much greater than for any earlier machine
designed for short-circuit testing. As
shown by Figure 2 of the paper, the 3-phase
symmetrical current 5 cycles after short
circuit is still more than 70 per cent of the
1/2-cycle value. It is, therefore, interesting
to analyze the part played by the damper
winding in securing this result.
To obtain the desired initial short-circuit
current, at the least cost, it was necessary
to use relatively shallow (low-reactance)
field slots. This gave space for only a
limited amount of field copper, so that the
field resistance is relatively high. On this
basis, the generator would be expected to
have a higher rate of decrement of field
current on short circuit than for a normal
machine of the same rating.
Since the damper winding is uninsulated,
its ratio of copper to slot area is greater than
for the field winding. Also, a given amount
of copper is more effective in the damper
winding than in the field, because of its
lower end-turn resistance and higher effec-
tive turn-ratio. Therefore, all available
slot space above that required to give satis-
factory field heating was devoted to the
damper winding. In this way, the resist-
ance of the damper winding, referred to the
primary, was made not much larger than
that of the field.
As the following approximate equations
for the short-circuit currents and their
decrement ratios show, the results depend
on the resistance of the field and damper
windings in parallel, and are affected very
little by which of the two has the higher
resistance.
Let
E = per-unit alternating current voltage before
short circuit
I" =per-unit subtransient current (symmetrical
alternating current)
I'=per-unit transient current
Io=per-unit sustained symmetrical 3-phase current
Xd= per-unit 3-phase synchronous impedance
X=per-unit 3-phase leakage reactance of damper
winding alone
X + X1 = per-unit 3-phase leakage reactance of field
winding alone
RD= per-unit resistance of damper winding alone
RF per-unit resistance of field winding alone
=
c = 2rf = 377 for 60 cycles
It is assumed that all the damper-winding
reactance links (is mutual with) the field
winding also, and that the induced currents
in the solid iron rotor are negligible.
The 3-phase symmetrical per-unit short-
836 Kilbourne-New Large Short-Circuit Testing Generators
3. THE HEBBURN SHORT CIRCUIT TESTING PLANT,
H. W. Clothier. The Electrical Review (London,
England), May 1930.
4. HIGH-POWER INTERRUPTING CAPACITY TEST-
ING STATION OF THE: GENERAL ELECTRIC COMPANY,
G. F. Davis. General Electric Review (Schenec-
tady, N. Y.), volume 35, February 1932.
5. HIGH-POWER SHORT-CIRCUIT TESTING, V. A.
Brown, A. C. Ehrenberg. BEAMA Journal,
The British Electrical and Allied Manufacturers'
Association (London, England), September, Octo-
ber, November 1937.
6. HIGH-CAPACITY CIRCUIT BREAKER TESTING
STATION, J. B. MacNeill, W. B. Batten. Electrical
Enginieering (AIEE Transactions), volume 61,
circuit current is the sum oif three com-
ponents
ERDXI - IP2t a solid continuous blocking in short-circuit
Lpproximate
(RFRD)(X+Xl)X
it
Ee ,Pl17 +
RF 2XI
(RF+ Ro 2XJ
X+X(
and the steady-state current 1
The subtransient current deecrement rate
is
P2=(R+RD) [1 +RDX+
P1 LlRFRD~
Xi
approximate
and that for the transient cur -ent is
rent is
RFRD r RFX1
(RF +RD)(X+X1) l RE)+RF)XJ
approximate
If RD is large compared Ito RF, as in
generators of normal design,
P2 = RD/X1 approximate
and
P, = RF/X+Xl approximate
In this case, the subtransient decrement
rate depends on the damper winding alone,
and that for the transient current depends
only on the field. In the short-circuit test-
ing generator described in this paper, how-
ever, both resistances affect both decrement
rates. In either case, components of both
the transient and subtransient currents flow
in both the field and the damper windings,
while the sustained current flows in the
field winding alone.
L. T. Rosenberg (Allis-Chalmers Manufac-
turing Company, Milwaukee, Wis.): Based
on Figure 2 of the paper, the 4-pole genera-
tors described appear to have a saturated
subtransient reactance of about 61/4 per
cent. A lower reactance can be obtained
with a 2-pole machine. The subtransient
reactance of the 2-pole cylindrical rotor
machine described in a paper by Sterling
Beckwith was less than 2 per cent on its
nominal kilovolt-ampere base. A nominal
40,000-kva 2-pole generator with 2-per-cent
reactance would deliver the same initial
short-circuit current as the 125,000-kva
4-pole machine.
A number of the features employed are of
interest. The stator coil bracing undoubt-
edly is simplified by the cylindrical rather
February 1942, pages 49-53.
7. SOME FACTORS AFFECTING THE DESIGN OF
ALTERNATORS FOR SWITCHGEAR TESTING, V.
Easton. Journal, Institution of Electrical Engi-
neers (London, England), November 1942.
8. THE NELSON RESEARCH LABORATORIES OF THE
ENGLISH ELECTRIC COMPANY. Journtal, Institution
of Electrical Engineers (London, England), January
1948.
9. TURBOGENERATOR FOR USE IN SHORT-CIRCUIT
TESTING, Sterling Beckwith. AIEE Transactions,
volume 70, part II, 1951, pages 2016-20.
10. NEw HIGH-CAPACITY SWITCHGEAR TESTING
LABORATORY, V. L. Cox. AIEE Transactionzs,
volume 71, part III, 1952 (Proceedings 52-20).
than conical end shape. Some manufac-
turers have gone the other way and em-
ployed radial coil ends in order to provide
test units. Both methods greatly handicap
ventilation. We have found the conical
ends can be braced securely in the same
manner as all turbogenerator stator coils
using metal brackets lined with hard wood
cushioning liners forming several continuous
rings at each end, and with the coils lashed
to these brackets using bakelite coil spacers.
Adequate ventilation is obtained even with
the oversize spacers required to keep the
unit pressure safe under asymmetrical rms
currents of 86 times normal.
The effectiveness of the amortisseur
winding is extremely important during
single-phase
high initial currents onlyminimize
tests, notand to maintain the
retarda-
tion but also to protect the rotor wedges
and retaining rings from injury. By the use
of nonmagnetic steel retaining rings, the
author has confirmed our own belief that
in addition to reducing losses and finger
plate temperatures they are especially bene-
ficial at time of short circuits. The shrink
fit over the rotor body and end disk and
the use of steel wedges also agree with our
practice on turbogenerators.
REFERENCE
1. TURBOGENERATOR FOR USE IN SHORT-CIRCUIT
TESTING, Sterling Beckwith. AIEE Transactionts,
volume 70, part II, 1951, pages 2016-19.
R. L. Williams, W. F. Skeats (General
Electric Company, Philadelphia, Pa): The
first of the two testing generators described
by Mr. Kilbourne was placed in operation
in November 1951 and the second about
2 months later. Since that time these
machines have been subjected to about
700 short circuits, both singly and in parallel.
Many of these have been made at full
excitation with no external reactance be-
yond that of the bus to the test cells.
These are, of course, only the beginning, as
our development program is predicated on
an estimated 15,000 short circuits per year.
It is not difficult to appreciate that this
represents tremendous pounding of the
generators, and to realize that the great
amount of extra labor and cost going into
the building of these machines will have
been well spent. Nothing but short circuits
is manufactured in the development labo-
ratory but these must be produced in quan-
tity, at high severity, and on a reliable and
continuing basis.
A modern circuit breaker with fast re-
laying will clear a fault from 3 to 8 cycles
OCTOBER 195)2

after inception, and therefore, even though
tests may be made in which the circuit
breaker is tripped before the short circuit
is applied, it is as much the current 2 to 5
cycles after inception that determines the
usefulness of such a generator as described
by Mr. Kilbourne as the current in the first
Frequency-Shift, Carrier-Current
Equipment for Telemetering and
Other Control Type Functions
R. W.'BECKWITH
MEMBER AIEE
THE substantiated theories of fre-
quency modulation' have been ex-
tended to the transmission of coded and
other types of low-frequency signals. A
very narrow-band, frequency-shift, power-
line, carrier-current system has been de-
veloped. Theoretical work has been
done, sample circuits have been built, and
the simplest ones have been selected.
Transmitters and receivers have been
produced in sizable quantities and ap-
plied to power-line use. The first of these
now has had several years of successful
operation. As a result of field experience,
additional development work, and new
operating needs, an improved transmit-
ter and receiver have been designed.
OCTOBER 1952 Beckwith-Carrier-Current Equipment for Telemetering
Figure 1. High-
voltage 5-posi-
tion selector
switch for trans-
formers tops lo-
cated in outdoor
switchyard
loop. Furthermore, in practice in the field,
a circuit breaker faces a short circuit whose
a-c component decays relatively little from
inception to interruption at these times.
Circuit breakers are proportioned accord-
ingly, and therefore, while a small deviation
from this condition in the test circuit can
In the frequency-shift transmitter, a
Hartley oscillator is modified by the intro-
duction of a network of two crystals in
the feedback circuit to the grid. An ex-
planation of this circuit operation is given
later, and it is shown that oscillation is
controlled by the crystals at two frequen-
cies and that operation can be shifted
smoothly from one of these frequencies
to the other by means of a variable re-
actance circuit connected across the oscil-
lator tuned circuit.
As a receiver demodulator, a single
crystal is used in a bridge circuit along
with diode rectifiers to produce a true
crystal discriminator2 having all the char-
acteristics of a conventional discriminator
be tolerated without serious consequences,
a wide variation will create conditions whiah
are either unfairly severe in some respects
or inadequate in others. For this reason,
Mr. Kilbourne was asked to hold the a-c
component of short-circuit current at 5
cycles as close as possible to 75 per cent of
the value at 1/4 cycle. When this request
was made, it was realized that most of the
things that could be done to increase the
short-circuit current from a machine to a
given size had a strong tendency to in-
crease the sharpness of the decrement
curve. It is therefore with very high appre-
ciation that we note how closely Mr. Kil-
bourne has approached this goal. The
curve which he shows in Figure 4 makes it
possible to test three phase at maximum
short-circuit current with a decrement
curve quite comparable with those to be
found in our major generating stations and
makes possible, within the power delivered,
tests which are adequately severe in all
respects but seriously unfair in none.
Although deceleration as high as 6,000
rpm per second arises from alternating
torques, this is associated with a cyclic
exchange of energy back and forth be-
tween the mechanical kinetic form (W/wIc,2)
and the electromagnetic form ('/2LI2), and
the average deceleration over a number of
cycles is very much less, as is indicated by
Mr. Kilbourne's oscillograms. Maximum
frequency loss in a 5-cycle test at 60 cycles
is approximately 1 cycle. This is not
sufficient to invalidate test data or to re-
quire de-energization of the driving motor
at the time of a test.
except with a greatly magnified frequency
scale. An improved form of this circuit,
having better efficiency and freedom from
effects of interfering signals, is described
in later paragraphs.
The first circuit is used to form a fre-
quency-shift signal, keyed at rates up to
about 30 cycles per second. The per-
centage shift in frequency is kept very
small to conserve frequency spectrum,
and the second circuit is used to detect
this small shift in frequency. This com-
bination forms a channel having excellent
properties for transmission of telemetering
signals.
In the Appendix a thorough explana-
tion of the impedance characteristics of a
piezoelectric crystal is given. The com-
plete 3-dimensional impedance -frequency
function is shown in two forms to aid in
Paper 52-218, recommended by the AIEE Carrier
Current Committee and approved by the AIEE
Technical Program Committee for presentation at
the AIEE Summer General Meeting, Minneapolis,
Minn., June 23-27, 1952. Manuscript submitted
March 25, 1952; made available for printing May
12, 1952.
R. W. BECKWITH iS with General Electric Com-
pany, Syracuse, N. Y.
This material is the major part of a thesis presented
to the Faculty of the Graduate School of Syracuse
University in partial fulfillment of the requirements
for the degree of Master of Electrical Engineering.
837