Table of Contents

Exciters

SECTION PAGE #
1. Introduction 1

2. Basic design of exciters 2

3. Malfunction behavior of exciters 5

4. Process effects on exciters 13

5. Mechanical effects on exciters 15

6. Information required when diagnosing exciters 17

REV C 129283
Exciters Page 1

Introduction

In this section, we want to investigate exciters in much the same way that we have
investigated the other pieces of machinery covered so far. Exciters tend to be reliable
pieces of machinery that run for the life of the turbine-generator without causing much
trouble. How to recognize exciter problems before they take the generator off-line, and
what to do about some of these problems, will be the focus of the following pages.

REV C 129283
Page 2 Applied Diagnostics

Basic Design

The purpose of the exciter is to generate and supply dc power to the generator's
rotating field. There are three types of exciters commonly in use. The first type is a
rotating commutator exciter which generates dc power directly and is much like the
automobile generators used years ago. The next type is a brushless exciter which
generates ac power and then rectifies the ac power to dc for the generator field's use.
Finally, there is a static exciter in which the dc power is made in non-rotating rectifiers
and is supplied to the generator field via rotating collector / slip rings. Each of these
different types of exciters is significantly different in its design and construction, and
therefore, exhibits markedly different vibration responses.

In this section, we will examine the parts of excitation systems (exciters) that are
connected to the turbine/generator and how these machines are designed and built. From
this you will be more able to understand why exciters behave the way that they do.

Figure 1 Gear Driven Exciter

Exciters are relatively light and flexible compared to the generator and as such are
very much affected by generator vibration. The typical exciter has one bearing (tilting
pad or shoe type) on the outboard end and shares its inboard bearing with the generator.
The exception to this is in the static excitation system where the collector/slip rings are
overhung from the generator shaft.

REV C 129283
Exciters Page 3

Figure 2 Slip Rings of a Static Exciter

Both the brushless exciter and the rotating commutator exciter are complex in their
construction and have many bolted on parts. These parts can come loose and fly off (not
common) or, in the case of the capacitors, diodes and fuses, need replacement
occasionally. When any of these parts are replaced, an unbalance condition can be
introduced if the replacement parts are not within a few grams of the weight of the
original part. On any rotating exciter that uses brushes, it's important that the
commutator/collector surface be concentric and smooth, as a rough surface can produce
vibrations in the exciter and at the adjacent generator bearing. Check the manufacturer's
recommendations for correct surface conditions. Rough commutator/collector surfaces
can cause an increase in brush wear rate, which could lead to brush arcing and a possible
increased field current. Brushless exciters, as the name indicates, do not use brushes
(except for ground detection) and, therefore, are not subject to this problem.

Typically, the various wheels of the rotating exciter are shrunk and keyed to the
exciter shaft. This rarely causes a problem. However, keys and keyways do cause shaft
asymmetries, and shrink fits can loosen, particularly if they are not properly designed,
constructed or installed.

REV C 129283
Page 4 Applied Diagnostics

Excitation equipment that couples directly to the generator shaft usually forms a
rabbet fit between the exciter shaft and the generator shaft. The coupling dowels/bolts
usually thread into the end of the generator shaft. Because of this design, centering the
two shafts is not usually a problem as long as the dimensions of both coupling halves are
correct. Any lack of parallelism between the two coupling faces can cause the end of the
exciter shaft to orbit and can cause high 1X vibration. Usually, a swing check is
performed to assure that the exciter shaft will run straight with the generator shaft.
Exciter couplings are usually shrunk and keyed to the exciter shaft. This feature rarely
causes a problem.

The exciter bearing support and the other major non-rotating components bolt to
the exciter base. The exciter base is bolted to sole plates in the concrete floor. Alignment
with the generator is maintained during operation by means of a transverse anchor that
allows only axial movement of the exciter assembly.

REV C 129283
Exciters Page 5

Malfunction Behavior of Exciters

In this section, we will examine the malfunctions that can occur in exciters. We
will also examine what can cause exciters to manifest that behavior, and what can be
done to correct undesirable behavior. In this section, we will discuss the following
malfunctions that exciters may experience:

A. Unbalance
B. Rubs
C. Brush Effects
D. Misalignment
E. Fluid-Induced Instabilities
F. Shaft Cracks

A. Unbalance

1. Brushless Exciters

Like any other piece of rotating equipment, exciters must be balanced in

order to run properly. Unlike many other pieces of rotating equipment there
should never be any rubbing, erosion or wear to alter the exciters balance state.
Therefore, once an exciter is balanced, it should stay balanced until something is
done to it that alters its balance state. Routine maintenance of brushless exciters is
a likely time to alter the exciter's balance state. The routine maintenance of a
brushless exciter usually includes the removal and testing of the diodes, fuses, and
capacitors. These components are bolted to the exciters various wheels. As long
as these same components are returned to the exact location that they were
removed from, using the same hardware (e.g. bolts and washers), there should be
no measurable change in the exciter's balance condition. Usually all of the
removable components will have a number or letter on them, so they can be
returned to their original location. If there suddenly is a balance problem with an
exciter after routine maintenance, it is wise to check that all of the parts were put
back in the same place. If there is no numbering system, it will be very difficult
for anybody to know whether or not these parts were put back in the proper
location.

REV C 129283
Page 6 Applied Diagnostics

Figure 3 Brushless Exciter

Also, check to see if any of these components were replaced. If any were, how
much weight difference was there between the original and the replacement?
Usually, a few gram difference won't cause a problem. The only way to be sure is
to calculate the unbalance force generated using the mass difference as an
unbalance mass. In the brushless exciter, there often is a considerable amount of
blocking in the various wheels. Sometimes this blocking gets loose and moves
around. Typically, the blocking doesn't move far. The blocking doesn't weigh
very much, so its movement generally won't cause a problem, but it's something
that should be looked at.

REV C 129283
Exciters Page 7

Figure 4 Slip Rings of a Static Excitation System

2. Rotating Commutator Exciters

The rotating commutator type exciter is very much like a dc motor or the
generators found on automobiles years ago. There usually is nothing to remove
from the rotating group for routine maintenance to create a balance problem. If a
piece did come off by itself, this would likely be a major catastrophic event that
would not be difficult to detect. Occasionally, depending mostly on brush spring
tension and cooling air contamination, the commutator slip rings may need to be
ground to smooth their surface and make them concentric with the rotor. This
operation is usually done as follows: With the exciter coupled to the generator, the
turning gear is engaged and a minimum cut is taken off of the commutator area, so
that the commutator is straight and true. Basically, the turbine is being used as a
big lathe. Anytime metal is removed from a rotating part, an unbalance condition
could be introduced in that part, so care must be exercised. The rotating
commutator-exciter is really nothing more than a dc generator adapted to special
use. The rotating commutator exciter acts just like a dc generator as it can exhibit
the same malfunctions in the same way as a dc generator. A hot spot on the rotor,
REV C 129283
Page 8 Applied Diagnostics

caused by a short, can make the rotor bow and generate 1X unbalance. An
unbalanced electrical field created by a short or open can cause the rotor to bow
because the magnetic center no longer coincides with the center of rotation.

3. Static Exciters

The rotating collector slip rings of the static exciter are the simplest of all
from the standpoint or the rotating parts. Often there are balance weights installed
on the outboard end of the collector slip rings. The most common way for this
type of exciter to get out of balance is for one of the weights to come off or be
removed. The locations of these balance weights should be recorded, so if an
unbalance condition ever does arise, loss of weight can be confirmed or denied.

There may be a fan assembly attached to one end of the collector for
cooling. Usually there is no need to remove or replace any of the fan blades.
Typically these blades don't fail, but, in the case of problems, it won't hurt
to verify that they are all still in place. The static exciter, as in the case of
the rotating commutator type exciter, uses brushes, and therefore, may need
to have the slip rings reground from time to time. The same basic procedure
used on the rotating commutator exciter for commutator grinding is used,
and, if done wrong, could cause an unbalance condition. If the collector slip
rings are machined while there is a bow in the generator rotor, an unbalance
condition can be created. In this situation, the collector rings would be
concentric when turned but would be off center when the bow came out of
the generator shaft.

B. Rubs

Rubs in exciters are usually confined to exciter bearing oil seal rubs and
generator bearing oil and hydrogen seal rubs. Rubs usually have a great effect on
exciters. There are basically two different reasons for this. First, is the case of the
exciter bearing oil seal rub. The exciter shaft is relatively light and flexible. The
impact created in the typical rub easily causes the shaft to rebound in classical rub
fashion. On exciters with one bearing, a generator hydrogen seal rub may move
the exciter shaft centerline to a less eccentric position in the bearing and greatly
reduce the system direct stiffness. Therefore, the vibration response amplitude will
change. Exciter bearings are often lightly loaded, so a little change in centerline
position can make a big difference in vibration amplitude.

REV C 129283
Exciters Page 9

Figure 5 Orbit Showing a Rub in an Exciter Bearing Oil Seal

Figure 6 Bode Plot Showing a Rub in an Exciter Bearing Oil Seal

REV C 129283
Page 10 Applied Diagnostics

Figure 7 Exciter Shaft Bending Graphic

A rub in the adjacent generator bearing seal, or any disturbance in the
generator, is manifested in the exciter through a different mechanism.
Consider the exciter-to-generator coupling. This is a rigid coupling that
allows no angular misalignment. The angle the generator side of the
coupling assumes, due to a deflection in the generator rotor, is the angle the
exciter side of the coupling must also assume. In the course of assuming the
same angularity as the generator side of the coupling, the moment created
can reduce or increase. Reduced loading on the exciter bearing may cause
the shaft to be in a less stable (lower eccentricity) position in the bearing.
The exciter shaft is generally much more flexible than the generator shaft,
therefore, the generator activity will be able to drive the exciter activity. A
rub, either in the generator outboard bearing oil seal or hydrogen seal or in
the exciter bearing oil seal, will tend to modify the exciter bearing system
stiffness and change the exciter bearing vibration amplitude, particularly, at
or near, a resonance.

C. Brush Effects

Like any other piece of electrical equipment that use brushes to

transfer power from the stationary parts to the rotating parts, exciters using
brushes are subject to problems with brushes bouncing and arcing. To work
properly, brushes need a smooth clean surface with a little ambient humidity.
The contact pressure between the rotating part and the brush must be
correct, and the amount of power transferred must be within the capacity of

REV C 129283
Exciters Page 11

the brush. The brush material must be correct for the type of collector or
commutator material being used. If all of these conditions are met, the
brushes shouldn't chatter, arc or overheat. Usually this is the case, and
brushes are often ignored because they are reliable. When brushes start to
bounce or chatter, the vibrations caused can often be seen on the exciter
bearing vibration signal. When the brushes bounce, the voltage regulator
output fluctuates to try to keep the generator output voltage constant. Any
changes in the field voltage or current can affect the magnetic field
generated and the rotor vibration. Brush disturbances of this magnitude are
uncommon and so extreme that the arcing alone should alert someone to the
problem. Usually, someone notices brush problems before it gets this bad.

D. Misalignments

Misalignments affect exciters in the same way as any other piece of

equipment. Exciters are unique in their construction and their sensitivity to
misalignment. Exciters that have one bearing of their own and share a bearing
with the generator usually require a "swing check" to be performed any time the
coupling has been broken. A swing check indicates the angularity between the two
coupling faces by reading the amount of runout of the exciter shaft at the exciter
bearing. Any angularity between the coupling faces will cause the end of the
exciter shaft to move in an orbital motion. Correcting the amount of runout is
usually done by adjusting the torque on the coupling bolts. Concentricity between
the two coupling faces is not usually a problem because of the rabbet fit between
the two that is typically used. Any lack of concentricity between the two coupling
halves can produce increased 1X vibration in the exciter and adjacent generator
bearing.

Exciters are unique, as the outboard bearing pedestal is movable in three

axes on the exciter base. The exciter assembly is also removable, and is usually
removed when the generator is disassembled. All of the major exciter pieces also
bolt to the exciter base and, therefore, create more misalignment opportunities.

Proper alignment of the exciter shaft is essential, because exciter bearings

tend to be lightly loaded. Misalignment is a major problem with an exciter. When
the misalignment puts the shaft center near the bearing center (low eccentricity
position), this decreases the threshold of stability, making the rotor susceptible to
fluid-induced instabilities. Exciter shafts are typically bolted to the end of the
generator; because of their lower stiffness, exciter shafts can reach high amplitudes
very quickly. Overhung collectors used in static excitation systems are not usually

REV C 129283
Page 12 Applied Diagnostics

removed from the generator shaft and, therefore, don't usually create any problems.
This type of collector has no bearing to mis-align, misalignment is not a problem.

E. Fluid-induced Instabilities

As we mentioned earlier, exciter bearings tend to be lightly loaded and

exciter shafts tend to be flexible. These things make the exciter bearing, in the one
bearing design, a prime candidate for a fluid-induced instability. To help alleviate
this, the exciter bearing is often a shoe or tilting pad type. These types of bearings
resist fluid-induced instabilities (whirl/whip) because the circumferential flow of
the lube oil within the bearing is interrupted. When a fluid-induced instability
occurs, the action will be easily seen on the exciter bearing vibration monitoring
because the exciter shaft is light and relatively flexible. The action caused is likely
to be violent enough to also be seen on the generator bearing adjacent to the
exciter. Usually, if the bearing clearance and the oil supply temperature are
correct, the "instability" problem can be corrected by raising the elevation of the
exciter bearing slightly. This should only be done when the situation has been
carefully reviewed, preferably by the original equipment manufacturer. Any time
the bearing elevation is changed, the bearing in question and the adjacent bearing
metal temperatures should be closely monitored.

F. Shaft Cracks

Exciter shafts are candidates for shaft cracks because of the way couplings
and wheels are usually shrunk and keyed onto them. Exciters shafts don't tend to
crack because they are relatively flexible, and are not subject to extreme thermal
transients. A crack in an exciter shaft should be easily detected using proximity
probes and a Keyphasor® transducer because of the flexibility of exciter shafts.
The best way to avoid a crack is to assure proper alignment.

REV C 129283
Exciters Page 13

Process Effects
The process is defined as any thing or an operating condition that interacts with the
exciter but is not part of the exciter. The items listed below highlight the system concept
of machinery diagnostics. The exciter is usually very much affected by the generator's
vibration. The only way to make a competent diagnosis of the exciter is to examine the
exciter and the generator it is connected to, as well as the related process systems. This is
necessary, so the cause of any problem can be tracked to its source. If the root cause of a
problem is not identified, only the symptoms of the problem get fixed.

A. Unit Load

Figure 8 Excitation Voltage Figure 9 Excitation Current

The most obvious process effect is a change in unit load. A change in the
unit's load means that the loading on the exciter has also changed. A change in
load can change the generator's vibration response, which will affect the exciter's
vibration response. Exciters that employ brushes can be affected by a load change
due to a change in brush loading. As a brushes power throughput changes, so does
the amount of arcing and bouncing. When brushes are working correctly, this will
not be a problem. If brushes are not working correctly, if they are arcing and
bouncing excessively, a change in load can make a big difference.

The cleanliness of the cooling air supplied doesn't have much of an effect on
a brushless exciter. However, on brush type exciters, the cleanliness of the cooling
air can make a big difference. Brushes are most often made from graphite, a mild
REV C 129283
Page 14 Applied Diagnostics

abrasive, to help keep the commutator slip rings clean and a binder to hold them
together. Graphite is very soft, so dirt and contamination on the ring will probably
cause accelerated brush wear. Dirt contamination can cause brushes to not slide
freely or to wear at the contact point in the brush holder. This can lead to reduced
contact pressure between the brush and the commutator slip rings, which in turn,
can cause reduced brush current carrying capacity. When any single brush cannot
carry the full amount of power it's supposed to, the other brushes must take up the
slack, possibly making any existing problems that they have worse. Brushes need
a little moisture to wear properly because moisture acts as a lubricant. Ambient
humidity and air cleanliness varies widely around the world, therefore, brushes are
made with different compounds. If the brush material is changed on a machine, all
the brushes must be changed to prevent an unbalance in the current distribution
between the brushes.

B. Oil Temperature

Oil temperature changes affect the whole machine because lube oil systems
are almost universally common to all bearings on a turbine generator. On an
exciter with continuous film bearings, the change of oil viscosity, related to the
change in oil temperature, can affect the exciter directly through a change on the
shaft position and the fluid average circumferential velocity ratio, or through a
change in the generator's vibration response.

REV C 129283
Exciters Page 15

Mechanical Effects on Exciters

In this section, we want to examine the mechanical forces that can alter an exciter's
vibration response. The mechanical forces we will be dealing with here come from
outside the exciter and are not typically generated by the exciter itself.

About the only mechanical effect manifested on an exciter is misalignment. To

better understand how alignment or misalignment occurs in an exciter, let's look at how
the typical exciter is built and installed. (Note: The collector ring assemblies of the static
exciter don't really apply to this discussion). Most of the time exciters are built so that
they can be moved to facilitate generator maintenance without major disassembly of the
exciter. This means that the major components of the exciter will be bolted to a base
assembly that can be moved. The typical base assembly rests on sole plates that are set
into the turbine floor. Usually, there will be a transverse anchor so that expansion of the
exciter happens along the axis of the generator. The exciter base, when replaced, is
usually located with alignment dowels that force the base to the correct location.
Typically, there are no shims between the base and the sole plates, so shimming is not
usually a problem. The exciter sole plates, like most sole plates, are solidly formed and
grouted into the floor and almost never move.

Figure 10 Brushless Exciter

REV C 129283
Page 16 Applied Diagnostics

Since the exciter is attached to the turbine floor and the turbine-generator rests on
pedestals, there is a possibility of differential movement between the exciter and the
generator. If the generator pedestal moves, the turbine-generator alignment will also be
affected. Cleaning the sole plates and mating surfaces of the exciter base is a good idea.
The only piping that bolts directly to the exciter (bearing pedestal) is the lube oil piping.
While the lube oil piping is usually flanged and rigid, it's not usually strong enough to
move the exciter. Exciter air cooling piping, though larger and more rigid than the lube
oil piping, doesn't directly connect to the exciter. The exciter air coolers are usually
mounted in the exciter house, which is separate from the exciter itself.

The exciter bearing pedestal is bolted to the exciter base and is rarely moved,
unless to realign the machine. If the realignment is done properly, this will not be a
problem. The other stationary components bolted to the exciter base are unlikely to
evermove and can't easily affect the alignment.

REV C 129283
Exciters Page 17

Information required for exciter diagnosis

In this section, we want to list the items that are necessary or useful to look at when
trying to diagnose a problem in an exciter. These are as follows:

A. Overall vibration trend and baseline data

Overall vibration trend and baseline data should be compared against

new and historical data. This includes startup and steady state data.

B. Generator bearing vibration data

The generator can have a strong effect on the exciter vibration. The
generator bearing vibration also needs to be evaluated to see if it is the cause
of any vibration seen in the exciter.

C. Shaft centerline movement

Shaft centerline movement should be compared for current operating

conditions versus historical data. This information may indicate the
alignment condition of the exciter.

D. Orbit plots

Orbit plots should be compared for current operating conditions

versus historical data. This is also a good way to see the effects of alignment
as well as the shaft activity in the bearing.

E. Bearing oil supply and drain temperature

Bearing oil supply and drain temperature should be compared against

current operating conditions versus historical data, and versus design
conditions.

F. Bearing metal temperature

Bearing metal temperature should be compared against current

operating conditions versus historical data, and versus design conditions.

REV C 129283
Page 18 Applied Diagnostics

G. Visual inspection of brush activity

Brush activity should be compared as best as possible against

historical inspections to see if the brushes are arcing more than normal.

H. 1X and 2X amplitude and phase

The current data should be compared against trend and historical data.

I. Balance resonant frequencies

Compare the current balance resonant frequencies with historical

values. This will require a shutdown or startup which may not be possible.
Startup and shutdown data should be obtained every time the unit starts up
or is shut down.

J. Generator load, amps, output voltage & VARS

Compare the current electrical operating conditions against the normal

and historical values.

K. Voltage regulator output

Compare the voltage regulator output to normal and historical values.

REV C 129283