A deeper insight into EL CID

G. K. Ridley, Consultant, UK D. R. Bertenshaw, ADWEL International Ltd, UK

EL CID is now a familiar technique for monitoring stator core condition, but in some circumstances, peculiarities may arise in the result. Users will benefit from a full awareness of these aspects, and this paper aims to bring them more fully into focus.

he application of the electromagnetic core imperfection detector (EL CID) technique invented by Sutton [19801] in the late 1970s is now familiar to many manufacturers and users of large rotating electrical machines. Over the years a number of initially puzzling phenomena have been observed in the results, particularly with respect to large diameter salient-pole machines, which are common in hydroelectric schemes. There have also been some interesting features encountered in results from turbogenerators. While all the phenomena observed have now been defined and analysed by Ridley [20042], the purpose of this paper is to bring these matters into deeper focus so that EL CID may be used to greatest advantage. Some aspects may be already fully identified, but are included for completeness. It is assumed that the basis of the technique is familiar, that is, in essence the stator under investigation for soundness of its interlaminar insulation has a circumferential flux induced in it and any damage to the insulation allows a circulating fault current to flow (see Fig. 1). The magnetic fields from both the circumferential flux and fault current are detected by a Chattock potentiometer (also known as a Rogowski Coil), and by phase separation the magnitude of the fault defect may be determined.

Fig. 2. Alternative forms of excitation winding.

Appendix 2.1 of Ridley 20042]. The required value of volts per turn (Vt) is given approximately by [12.5 machine line voltage in kV] / [Stator winding series turns per phase], assuming that the combined spread and chording factor [K] is 0.926. Vt is inversely proportional to K.

2. Form of excitation winding

Several forms of excitation winding have been used (Fig. 2). In essence there are only two basic types. One comprises a bundle of conductors passed through the stator bore along the longitudinal axis (Fig. 1c). The other consists of conductor turns, passing through the bore but wrapped closely around it (Fig. 1b). Electromagnetic field theory shows that for the first type, the magnetizing force [H] is constant, whether inside or outside the iron core [see Appendix 5.1 of Ridley 20042). For the second configuration of the excitation winding, it can be shown [see Appendix 5.2 of Ridley 20042] that while the magnetizing force within a homogeneous iron core is approximately constant, outside the core it is substantially zero. But electrical machine cores are not homogeneous. They are built from a large number of segmental laminations, with inherently circumferential air gaps between segments, as well as longitudinal air gaps as a result of the interlaminar insulation and ventilation ducts. In addition, the bore of the core is slotted to take the stator winding. Thus, regardless of the form of excitation winding applied, the electromagnetic field is non-uniform. Moreover, the turns of the second basic type of excitation winding (Fig. 1b) are not usually wound close to one another. This causes the magnetizing force to vary across the core section. In a practical situation, therefore, whatever the form of excitation winding, the resultant electromagnetic field comprises a main circumferential flux through the core, as well as leakage flux spilling into the air surrounding it. Application of the sensor to the stator bore detects this leakage flux.

1. Magnitude of electromagnetic induction

Historically, the available excitation source during the early development of EL CID was such that the magnetic flux induced in the stator iron was about 4 per cent of the normal operating value, and this has become the standard. The EL CID results are approximately proportional to the level of flux induced. Therefore, it is acceptable to carry out the test at other than 4 per cent flux, but the results are then scaled as necessary. The degree of electromagnetic induction is determined by setting the excitation volts per turn in accordance with well known electromagnetic theory [see

3. EL CID vector diagram

Fig. 1. Typical interlaminar defect with circulating current.
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Initially the relevant vector diagram, relating the electromagnetic fields of the main flux and that produced by fault current () in the laminations, was conceived
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4. Stator winding circulating current

The observation was made, early in the experience of applying EL CID to hydro generators, that the PHASE value sometimes varied significantly and cyclically from slot to slot around the core, that is, circumferentially, which was contrary to expectation. This variation was occasionally sufficient to give negative values. Dr. T. W. Preston recognized that this could not occur without the presence of an electrical current to drive the flux in a direction opposite to that of the applied excitation. It followed from this that there must be current circulating in the stator winding, when present during the EL CID test. This proved to be possible when the stator winding includes parallel circuits, and was verified by establishing that the pattern of circulating current corresponded closely to that of the varying PHASE values (Fig. 3). It was further verified, on request to Dr. Preston, by a finite element analysis of a wound stator subjected to circumferential magnetic flux. The effect has been further verified in the field both on turbo-generators and hydro generators. Bertenshaw and Sutton [20043] describe how the effect was induced in a simple turbo-generator without parallel windings, but where the phases were all shorted to earth for safety. In this case, when the excitation cable was not placed axially central to the bore, the asymmetric induction caused current to flow between the phase windings, giving negative PHASE values in one region (Fig. 4). An analysis of the winding layout and currents showed that up to 0.75 A was flowing, which was able to explain the phenomena. As shown in Fig. 4, the correct central orientation of the excitation winding effectively eliminates this effect. Bertenshaw and Sutton [20043] also showed in a study of a large hydro generator with seven parallels that the inevitable effect of core splits is to induce some circulating current in any windings present, as a result of magnetic asymmetries in these regions. These values may only be deduced if the winding arrangement is known. However, in all cases, the presence of the winding is to introduce a constant standing signal on both the PHASE and (to a lesser extent) the QUAD values for the whole slot, and if this standing value is subtracted, localized core faults may still be determined.

Fig. 3. Circulating current effect on EL CID values.

Fig. 4. Circulating currents in a small turbo-generator.

as a simple orthogonal relationship, comprising PHASE [P] and QUAD [Q] vectors respectively, placed at 90 to each other. The PHASE value was proportional to the excitation current [Ie]. QUAD was proportional to the fault current (). It was always understood that contains an in-phase component, but this was considered negligible, compared with the quadrature component, since the fault path through the fault, stator laminations and corebuild (or key) bars is predominantly resistive. Test results indicated, particularly at joints between the sections in large diameter hydro generators, that the phase relationship was more complex. The relationship, for zero fault current, was identified by a characteristic line, cutting the PHASE axis at a value other than zero. This is basically the magnetic potential difference [mpd] which would be the constant PHASE value [Pe] if the permeability around the core was constant, and there was no fault current. Pe is calculated as [Magnetising Ampere-turns / Number of Teeth (or Slots)] = AT / S. Thus, the equation of the characteristic line is given by P = Pe + RQ, where R is the slope of the line. Ridley designated this as the zero line, applicable for no fault current (). The PHASE value at zero QUAD value is modified because of the effect of core joints and the presence or otherwise of the machine rotor during the EL CID test [see Section 7.6 of Ridley 20042]. To develop a comprehensive vector diagram, another factor had to be recognized and introduced (see below).

5. Further development of the vector diagram

The significant effect of the stator winding on EL CID test results identifies the test set-up as a transformer with its secondary winding either open-circuited or short-circuited. The basic vector diagram is obtained from well known transformer theory, and involves a reversal of the standard phase rotation to correspond to that assumed in the original work. It should also be recognized that, whereas current induced in a transformer secondary winding has the opposite sense to that of a primary winding, vectorially the two add when referred to the same base. Thus the EL CID sensor picks up circulating current and fault current signals which are negative in relation to the excitation current, but these have to be reversed when drawing the vector diagram. Account must also be taken of how the reference PHASE vector is established. This is derived from either the PHASE component of the electromagnetic field at the bore as detected by an aircored coil, or from the excitation current obtained by a current transformer placed round the excitation cable. Each case requires separate consideration.
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Fig. 6. EL CID vector diagram taking account of circulating current with PHASE reference set to the excitation current.

Fig. 5. EL CID vector diagram taking account of circulating current with PHASE reference set to the leakage flux.

5.1 Air-cored reference coil

In this case, the reference vector does not contain a component corresponding to the portion of excitation current required to establish the core loss in the iron, as it produces no flux. The detected flux does contain any existing contribution from stator winding circulating current. The PHASE and QUAD axes are identified as for an operating point where fault current is zero, as seen in Fig. 5. The vector diagram for that location is for a particular value of circulating current. At another location with a different value of circulating current, the operating point will move in the direction of the circulating current vector. This identifies the zero line, which is thus theoretically justified. When there is fault current [], the corresponding vector is added in a direction perpendicular to the basic flux vector. This is not at right angles to the established PHASE axis, thus the QUAD value comprises components from both the circulating current and the fault current. Since the stator winding circulating current is constant for each particular slot, the PHASE value along that slot is not varied by circulating current, as it is from slot to slot. Hence, by removing the mean QUAD value at each slot, the maximum value is derived approximately from the total variation in the QUAD reading. The EL CID software has a facility for readily achieving this. If the value appears to point to a defective region, it can be determined more accurately from localized PHASE and QUAD values obtained by use of one of the small hand-held Chattock sensors. If there is no stator winding circulating current, the essential vector diagram is that of a transformer with an open-circuited secondary winding. In this case, the PHASE value is essentially constant and QUAD values are nearly equal to .

siderations). Moreover, it is possible that there may be some net fault current also reflected in the excitation current. In any case, the basic reference vector is the excitation current [Ie], which includes an orthogonal component of current required to establish the iron loss. The vector diagram in Fig. 6 is drawn on the assumption that the PHASE reference is established where there is neither local stator winding circulating current nor fault current. As before, the variation of circulating current moves the operating point in its vectorial direction, which is again the zero line. The variation in the QUAD reading for a particular slot once again indicates the maximum value, which may merit closer examination.

5.3 The need to establish a zero location

For clarity this has been assumed above, but it is not strictly necessary. In general, it is desirable to minimize the QUAD value detected to maintain readings within usable graphical scale limits. In this context, it may be desirable to reset the PHASE reference to the electromagnetic conditions at some other particular location than that established initially. This is particularly the case at core joints, but care should be taken in case accuracy is diminished.

5.4 Circulating current direction

Circulating current is induced in locations such as a core joint, where there is disturbance of the magnetic field, and flows in stator winding parallel circuits, around which it must largely balance out. Consequently, there are regions of the stator where circulating current flows in the opposite sense. When introduced into the vector diagram, this opposite sense current causes the operating point to move into the 4th, or even the 3rd quadrant, as has been observed in EL CID test results.

5.2 PHASE reference from a current transformer round the excitation cable
A superficial consideration of stator winding circulating current indicates that there is no net value to be provided by the excitation current, since the currents sum to zero. However, they are induced only when the excitation is asymmetric, deliberately by the user or inevitably because of core construction. In this case, the coupling between excitation winding and generator windings is not symmetric and a portion of the circulating current must be contributed by the excitation winding (as would be expected on simple energy conHydropower & Dams Issue Four, 2005

6. Curvature of the EL CID trace

This factor, demonstrated in Fig. 7, was readily eliminated by moving a nearby salient-pole away from the core area under investigation. A finite element analysis established that salient-poles, when present, would always have such an effect [for details see Section 5.10 of Ridley 20042]. The magnitude of the effect is not always of significance, but it is an erroneous indication of deterioration in insulation condition towards the end of a core. It should, therefore, be recognized and eliminated.
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Fig. 7. EL CID trace curvature caused by the Pole Proximity effect.

analysis also showed an unexpected result. The form of the flux density distribution induced in the iron can be seen in Fig. 9. The surprising feature is that directly beneath the cable, the flux density is zero, whatever the spacing of the conductor from the iron. This explains the deep valley in the value of EL CID results in the neighbourhood of the cable. An understanding of this phenomenon helps to locate the position of the excitation cable, if it has not been recorded [see Fig. 20 in Ridley 20042].

9. Correlation of EL CID and HFRT results 7. EL CID trace axis slope

If the single bundle of excitation conductors, intended to be along the longitudinal axis of the core (see Fig. 1c), is offset and/or misaligned, the result is shown by a finite element analysis to be a slope of the EL CID trace axis. This distortion of the results (see Fig. 8) again raises a query regarding the core condition. A major concern of users of the EL CID technique is the degree of reliability with which EL CID results can be interpreted. Some users have found very high values, indicating a serious core interlaminar insulation condition, yet no indication of a hot-spot developing. It is now clear that there have been a number of possible reasons for this; most of which can be eliminated by virtue of the understanding reported here. A question still remains as to the value to place on the final value after taking account of all the modifying factors. Previous to the availability of EL CID, the quantitative method of assessing core condition was the high flux ring test (HFRT). Correlation between results obtained by both methods for a given machine has been sought by a world-wide questionnaire under the auspices of CIGRE, as reported by Ridley [20024]. Nevertheless, the result could only be given as a correlation band, rather than an exact relationship [see Appendix 4.1 of Ridley 20042]. An experimental study on the relative effectiveness of HFRT and EL CID test in a buried fault described by Bertenshaw et al [20045] shows that the relative effectiveness of the HFRT falls off rapidly if the defect is buried. A serious fault on a slot base (reading 520 mA of QUAD) was buried under a simulated winding. The HFRT value (at 0.8T rms) after nearly 2 hours of testing only reached a 6C rise above core body temperature, despite rising above 37C locally when measured by buried thermocouples. This shows that the HFRT is likely to give misleading re-assurance when the faults are buried in the core or under windings, and could explain much of the lack of visible symptoms of faults. However, the EL CID detection of buried faults down a slot base is only modestly attenuated, and correlated satisfactorily at 7C/100 mA. Consideration of the factors involved in an HFRT indicates that its results are dependent on the general ambient conditions, which include much more than ambient temperature. Other factors are the attitude of the core when tested, the location of the core in its normal operational situation or otherwise, the exis-

8. EL CID trace tails

Fig. 8 shows EL CID results for which the trace not only slopes for the reasons described above, but also has tails, which again indicates superficially core end deterioration. Such deterioration is possible, of course, especially if filing of the ends of the stator slots has been undertaken with a view to protecting the stator winding from possible damage by sharp corners. In the early experience of the EL CID technique, however, it was observed that the location of a transverse portion of the excitation winding, of the form shown in Fig. 1c, caused this type of distortion when the spacing from the core end was less than about 1 m. In the case of turbo-generators, this spacing is usually enforced by the relatively long stator winding overhang. For hydro generators, it can be quite difficult to achieve. Application of electromagnetic theory to the case of a current-carrying conductor located above an iron surface [see Appendix 5.6 of Ridley 20042] shows the justification for applying a spacing of at least 1 m. The

Fig. 8. EL CID results exhibiting trace axis slope and significant deviation at one end of the core.
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Fig. 9. Theoretical variation of flux density in an iron surface below a conductor.

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tence of air currents, core size, and the duration of the test. With regard to the last item, different personnel have quite different standards. It is recommended that a study is undertaken to identify the effect of these ambient conditions on HFRT results, so that correlation with EL CID results can be improved, thus enhancing the reliability with which the latter may be used. Nevertheless, the EL CID technique has been extensively applied and found to be a useful tool for monitoring core condition both for normal service and when under repair.

10. Conclusion
Although a number of phenomena in the EL CID results have been observed, they are now well understood, which allows their effect to be taken into account. The understanding gained permits use of EL CID in the same relatively simple manner as first proposed, and the results are consequently acceptable as a pointer to the core condition.

Eur. Ing. G.K. Ridley was a designer of large electrical rotating machines, mainly hydro generators, for nearly 40 years with BTH, Rugby, UK, and its successors, concluding his career as Design Manager. He has been a registered engineer with FEANI since 1990. He became a Chartered Engineer in 1960, subsequently achieving the status of FIEE (1970) and FIMechE (1992). He is also a Senior Member of the IEEE. He has been an active member of CIGRE since 1992, having undertaken worldwide surveys of bearing design and practice for large vertical hydro generators, and also the comparison of EL CID and High Flux Ring Tests (HFRT) results. He was invited to present a preferred subject paper on the latter topic at the biennial meeting of the CIGRE Session in Paris in 2002. Mr Ridley has had 37 papers published and in 2000 he authored a book entitled EL CID - Application and Analysis, the second edition of which was published in 2004. Since nominal retirement in 1994, he has served as an independent consultant on hydro generators, with a special interest in EL CID result analysis. 11 Hoskyn Close, Hillmorton, Rugby, Warwickshire CV21 4LA, UK. Eur. Ing. David Bertenshaw graduated with a B.Sc. (Eng) degree in Electrical Engineering from Imperial College, London University, in 1971. He was elected as MIEE in 1980, as FIEE in 1998, and is a Chartered Eur. Ing. He has spent many years in the development of lighting and control systems, and communications systems, as R&D and Engineering Director. He joined ADWEL International, UK, in 1998 and he now directs the engineering and commercial management of the companys stator core test systems. He has authored and presented 20 conference papers, is the inventor on six international patents and a member of national standards committees relating to EMC. ADWEL International, Park House, Greenhill Crescent, Watford, Herts WD18 8PH, UK.

G.K. Ridley

D. Bertenshaw

References
1. Sutton, J., EL CID: an easier way to test stator cores, Electrical Review, Vol. 207, No. 1, 1980. 2. Ridley, G. K., EL CID application and analysis, Ed: 2, ADWEL International Ltd; 2004. 3. Bertenshaw, D. R and Sutton, J, Application of the EL CID Test with Circulating Currents in Stator Windings, Inductica 2004, Berlin, Germany; June 2004. 4. Ridley, G. K., Hydro-generator EL CID results referred to High Flux Ring Test results, Proceedings, Session 2002 of CIGRE, Paper 11-201; August 2002. 5. Bertenshaw, D. R et al, Computational modelling of stator core faults in large hydro-generators and turbo-generators, Hydro 2004, Porto, Portugal; October 2004.

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