A1 TECHNICAL BROCHURE

Rotating electrical
machines

Guidance on High-Speed Testing

of Turbo Generator Rotors
Reference: 878
August 2022
Guidance on High-Speed
Testing of Turbo Generator
Rotors
WG A1.48

Members

B. ADAMS, Convenor UK G. CSABA SE

B. FENTON US J. PORTER UK
B. MANCUSO US G. YAN CN
N. SMIT ZA B. MOORE US
S. MITCHELL UK V. FERNAGUT FR
H. SHIMADA JP B. O’SULLIVAN IE

Copyright © 2022
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Disclaimer notice
ISBN : 978-2-85873-583-9
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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

Executive summary
Electrical engineers responsible for generator maintenance are often faced with a difficult question when
their generator rotors require maintenance: Whether to send it away for high-speed balancing and
testing or not. It is generally considered that doing so is a lower risk option, but there can be substantial
operational and financial pressures against doing so.
The requirement for testing a generator rotor following maintenance varies substantially across the
industry, with different methodologies being applied depending on the Owner/Operator, the Original
Equipment Manufacturer (OEM) and the geographical location of the equipment.
For example, some OEMs would not consider a high-speed balance was necessary for a full rewind as
long as the winding copper is reused, whereas some would recommend testing in a balance facility
should the retaining rings be removed for inspection, with no work on the winding having been carried
out.
One (now closed) rewind workshop informed the author that they had performed over 200 rewinds
without high-speed balancing, and none had suffered from balance issues. Whereas many operators of
plant will have examples where they have rotors returned to service with balance problems or electrical
faults.
The answer as to whether high speed testing is required is not straight forward and will be the
combination of many factors, of which one of the most prevalent is access to a balance facility. Europe,
North America, and Japan have a high level of access to balance pits whereas Latin America, Africa
and Asia Pacific do not.
For example, if a rotor is rewound in Germany, there are a variety of balance facilities available both in
Germany and in surrounding countries within a day’s transport via road or rail. The same rewind in, for
example, Indonesia, may require weeks of transport to the nearest facility. The cost of lost generation
will be a factor in the decision to balance or not, due to the time for balancing and transport and clearing
customs between countries.
This guide intends to simplify the decision making of whether to carry out high speed balancing on
generator rotors following work. In order to help this decision, information will be provided on:
 The scope of work which may be required on a generator rotor
 The problems which can arise following work
 The relative risk of problems depending on the work scope
 How to limit the risk of problems arising from work (QA)
 The geographical locations of high-speed balance facilities in the world.
A risk matrix is given in APPENDIX C which details the various work which might be carried out on the
rotor and the relative risk electrically and mechanically should the decision be taken to not high-speed
balance and electrically test the rotor.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

Contents
Executive summary ............................................................................................................. 3

Figures and Illustrations ..................................................................................................... 6

1. Introduction................................................................................................................ 7

2. Rotor Construction and Operation ........................................................................... 8

2.1 Rotor construction .................................................................................................................................... 8
2.2 Balance of rotors ..................................................................................................................................... 10

3. Potential issues ....................................................................................................... 11

3.1 Electrical................................................................................................................................................... 11
3.1.1 Rotor Ground Fault ............................................................................................................................ 12
3.1.2 Rotor Interturn Faults ......................................................................................................................... 12
3.1.3 Intercoil and Interpole Faults .............................................................................................................. 14
3.1.4 Preventing Electrical Problems .......................................................................................................... 14
3.2 Mechanical ............................................................................................................................................... 15
3.3 Transport of rotors .................................................................................................................................. 15

4. Maintenance / Repair of rotors ............................................................................... 17

4.1 Small repair work with retaining rings left in-situ ................................................................................. 17
4.2 Small repair / Cleaning with retaining rings removed .......................................................................... 17
4.3 Rewind using existing copper ................................................................................................................ 17
4.4 Rotor rewind with new copper ............................................................................................................... 18
4.5 Repair to forging ...................................................................................................................................... 18
4.6 New retaining rings fitted........................................................................................................................ 18

5. High speed testing................................................................................................... 19

5.1 High Speed testing facilities ................................................................................................................... 19
5.2 High Speed Testing Process .................................................................................................................. 23
5.2.1 Concentricity Checks ......................................................................................................................... 23
5.2.2 Pre-Balance Electrical Testing ........................................................................................................... 23
5.2.3 Preliminary Balancing ........................................................................................................................ 23
5.2.4 Heat Run............................................................................................................................................ 24
5.2.5 Overspeed ......................................................................................................................................... 24
5.2.6 Acceptance Run ................................................................................................................................ 24
5.3 Electrical testing at speed ...................................................................................................................... 25
5.3.1 Winding Insulation Resistance ........................................................................................................... 25
5.3.2 Winding Recurrent Surge Oscillograph (RSO) ................................................................................... 25
5.3.3 Winding Withstand Test ..................................................................................................................... 26
5.3.4 Air Gap Search Coil (AGSC or Flux Probe) Analysis ......................................................................... 26
5.3.5 Pole Drop Test ................................................................................................................................... 27
5.3.6 Winding Impedance Test ................................................................................................................... 27
5.4 Testing of brushless rotors .................................................................................................................... 28

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

6. Results of questionaire ........................................................................................... 29

7. Summary .................................................................................................................. 32
7.1 Potential problems .................................................................................................................................. 32
7.2 Considerations ........................................................................................................................................ 33

APPENDIX A. Definitions, abreviations and symbols ..................................................... 34

A.1. general terms ........................................................................................................................................... 34
A.2. specific terms .......................................................................................................................................... 34

APPENDIX B. Links and references ................................................................................. 35

APPENDIX C. Risk matrix ................................................................................................. 36

APPENDIX D. Questionnaire responses – testing .......................................................... 37

APPENDIX E. Questionnaire – experience on rewinds ................................................... 39

APPENDIX F. List of high-speed balance facilities of more than approx. 25T capacity 43

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

Figures and Illustrations

Figure 2-1 Rotor coil made up of several turns of copper strips ready to be insulated and installed .... 8
Figure 2-2 - Cross section of a rotor slot ................................................................................................. 9
Figure 2-3 - Rotor endwinding with retaining rings removed ................................................................... 9
Figure 2-4 - Slot liner insulation showing holes for ventilation ................................................................ 9
Figure 2-5 - Interturn insulation showing ventilation slots ....................................................................... 9
Figure 3-1 - heavily contaminated rotor endwinding ............................................................................. 11
Figure 3-2 - Endwinding insulation which has had a hole burnt through it causing a ground fault. ...... 13
Figure 3-3 - Damage to slot liner through wear ..................................................................................... 13
Figure 3-4 - Damage to slot liner through wear ..................................................................................... 13
Figure 3-5 - Migration of turn insulation ................................................................................................. 13
Figure 3-6 - Migration of slot liner insulation (copper will have been uninsulated at the other end) ..... 13
Figure 4-7 - Intercoil short due to contamination on the endwinding .................................................... 14
Figure 3-8 - Intercoil fault due to copper deformation ........................................................................... 14
Figure 5-1 - Map of the world showing locations of high-speed testing facilities for generator rotors .. 19
Figure 5-2 - Rotor being lowered into a below ground balance facility (300t) with a retractable concrete
roof. ................................................................................................................................... 20
Figure 5-3 - Rotor in a Balance Facility ................................................................................................. 21
Figure 5-4 - Balance Facility control room ............................................................................................. 21
Figure 5-5 - 30T balance facility ............................................................................................................ 22
Figure 5-6 - 340t high speed balance facility, external view above (with Steam Turbine) and internal
below (with a generator rotor) ........................................................................................... 22
Figure 5-7 - Balancing Tunnel – ............................................................................................................ 23
Figure 5-8 - example of an RSO plot showing a fault. In a fault free rotor, the red and blue traces
would overlap .................................................................................................................... 26
Figure 5-9 - Example of a flux probe test. The two waves should overlay. Any difference is given on
the blue "null" trace and can indicate a shorted turn ........................................................ 27

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

1. Introduction
In the manufacture of high-speed turbine generators, the rotors undergo a number of tests to prove their
integrity, both mechanically and electrically. The final tests are generally carried out at speed and
overspeed. These tests are carried out to prove that:
 All the components of the rotor have the mechanical integrity to operate within the full speed
range expected in normal operation, i.e., 0 RPM to rated speed +10% under normal
circumstances (although +20% is required during initial factory testing)
 The vibration levels of the rotor are acceptable through its run up, at rated speed and overspeed.
 Vibration levels remain within acceptable levels.
 The rotor is thermally stable (i.e., the vibration levels stay within acceptable levels as the rotor
heats up), and the thermal stability is repeatable.
 The integrity of the insulation is maintained throughout the speed range (i.e., there are no rotor
ground faults, and no turn insulation faults)
These tests are carried out at the factory to prove the equipment and limit the risk of operational issues
at the plant. The worst-case scenario is that a severe mechanical defect would cause destruction of the
rotor at site, causing catastrophic damage. This is a very rare occurrence in modern times, more likely
is that a problem may occur at site which causes high vibrations, either requiring the generator rotor to
be returned to a facility, or for operational limits to be imposed.
Following maintenance or repair work, the question of whether the rotor needs to repeat these tests
often comes up. The answer can be complicated and will depend on what work is carried out. In general,
carrying out high speed balance and electrical testing at a balance facility will usually be the lowest risk
solution. This is most likely to return a generator rotor to the power plant with the least chance of having
any previously undetected vibrational or electrical problems. Should defects be found during the work,
the rotor is within easy reach of facilities to perform remedial work.
This work is usually referred to simply as “balancing” and there are relatively few facilities around the
world capable of such works (further discussed in 5.1). This testing is expensive and may add months
to an outage program. It is common for engineers to face pressure to reduce outage times and costs
and consider whether high speed testing of the rotors is necessary. Furthermore, the rotor is a costly
strategic spare part, and the operator will want to have it ready to be used on site as required.
This working group was set up in order to explore these issues to help users of generators make a
better-informed decision as to whether they should opt to carry out high speed testing. The scope of this
working group was as follows:
1. Investigate:
 The scope of work which would require high speed testing
 The availability of high-speed testing facilities
 Any guidance already in existence on this subject
 OEM guidance.
 3rd party service provider’s guidance.
 The risk of introducing issues following work
 The risk remaining if high speed testing is not carried out
 Ways in which the risk could be mitigated.

3. Produce a risk matrix showing work carried and relative risk if high speed testing is not carried out.

4. Focus on two and four pole cylindrical rotor type turbine-generators.

A questionnaire was sent to the A1 study committee asking for information on what high speed testing
they would specify following rotor work and for details of their experiences.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

2. Rotor Construction and Operation

2.1 Rotor construction
Turbine generator rotors are constructed from large, machined steel forgings. These have slots cut into
the steel, within which strips of copper are inserted. These strips of copper are connected in series to
form a large coil of many turns (Figure 2-1), which are insulated from each other. Figure 2-2 shows a
cross section of a rotor slot with the interturn insulation, the slot liner insulating the copper from the steel
and a top packer insulating the copper from the rotor wedge. Figure 2-3 to Figure 2-5 shows examples
of the rotor winding, slot lining and interturn insulation.

Figure 2-1 Rotor coil made up of several turns of copper strips ready to be insulated and installed

The voltage of the entire winding is relatively low, usually a few hundred volts. As such, voltage stresses
are not a significant design issue. The slot liner ground insulation (which insulates the coils from the
steel forging) and the retaining ring ground insulation (which insulate the endwinding from the retaining
rings) only have to insulate a few hundred volts in normal operation, although it will be designed to pass
high voltage testing and transient voltages in the order of a few kilovolts. The interturn (turn to turn)
voltage will be in the order of a few volts.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

Figure 2-2 - Cross section of a rotor slot Figure 2-3 - Rotor endwinding with retaining rings removed

Figure 2-4 - Slot liner insulation showing holes for Figure 2-5 - Interturn insulation showing ventilation slots
ventilation

The major challenge for rotor insulation systems is the mechanical complications caused by the following
constraints:
 The rotor will cycle from standstill to operating speed, and occasionally to overspeed. At full
speed and overspeed there will be large forces acting on parts of the insulation systems. The
insulation will have to be able to be resilient against the peak of these forces and be able to deal
with the cyclic variations caused by operation.
 When the rotor is on turning gear, if the rotational speed is not fast enough to centrifugally lock
the rotor components into position, the coils and endwinding will experience some movement
through gravity as the rotor rotates. This movement can cause the insulation and copper to fret
and produce conductive copper dust.
Additionally, dusting can occur on longer rotors when on turning operation as there is a tendency
for the shaft to sag in the middle. Differing bending behaviour from the steel and copper
components will also cause the copper to fret and produce conductive dust.
Some generator rotor designs have a pre-stressed consolidated coil to mitigate the movement
of the insulation as described above.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

 Copper and steel have different coefficients of expansion. As such, when operating from cold
(off load) to hot (on load), there will be a difference in expansion over the length of the rotor.
The effect is made worse as the rotor winding will reach operational temperature first (as it is
being resistively heated by the current) and the steel will heat up more slowly due to the thermal
mass of the forging. The insulation system therefore must allow the free movement of the copper
in the slots even when the rotor is operating at full speed and subjected to large centrifugal
forces. If the movement of the copper is not free, it can lead to step changes in vibration as it
changes position (known as stick/slip), or it can lead to the distortion of the copper winding
(copper shortening or lengthening).
This mechanism as well as cyclic loading and turning gear operation can cause the copper or
the insulation system to ratchet out towards the end of the rotor. This will eventually damage
the insulation and leave the copper potentially exposed to the earth of the rotor.
 The insulation thickness is critical, as excessive insulation will inhibit the copper’s ability to
dissipate its heat to the cooling gas flows. Excessively thick insulation can also result in local
frictional “binding” of the coils which can inhibit axial expansion.
 Many designs will have cooling holes cut into the insulation, providing many areas where only
millimetres of air or hydrogen separate turns.
The design of a rotor insulation system is, therefore, somewhat delicate and can be prone to
contamination, insulation movement or from being punctured from raised surfaces (burrs, sharp edges
or brazing “bubbles” which have not been dressed out) leading to electrical shorts.

2.2 Balance of rotors

When operating at speed, the rotor needs to be finely balanced to prevent high vibrations. However, this
is made more complicated for a number of reasons. Firstly, the rotors are usually long and thin, and on
a large two pole generator, operating close to the third critical mode of operation.
Secondly as the rotor heats up through the mechanisms discussed above, the internal components can
move through thermal expansion, or can become stuck if their slip planes do not allow free movement.
Furthermore, if there are any electrical shorts between the turns of the winding, the resistive heat created
will not be evenly distributed throughout the rotor. If the rotor heats unevenly, the thermal expansion of
the steel will cause the rotor forging to bend slightly and create higher than expected vibrations.
For these reasons, it is important that rotors are tested in their vibrational performance from standstill to
running speed and overspeed as well as from cold to hot to ensure that the rotor does not produce high
vibrations which limit its operation in service.

This topic is discussed in more detail in Section 5

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

3. Potential issues
3.1 Electrical
As described above, there are a number of conflicting design requirements on a generator rotor; to
insulate the winding, carry high current, allow it to be cooled, retain it at high speed, and prevent
differential movement at low speed turning, yet still allow the copper to expand and contract freely.
Working on a rotor and especially a rewind is a long and largely manual process which introduces areas
for potential mistakes or areas of inconsistency such as:
 Burrs
 Poor brazing
 Insufficient insulation
 Slip planes not being correctly installed.
For the rewind or replacement of insulation on older rotors, it is possible that the insulation systems may
be upgraded with new materials. This may be due to modern equivalents, either through electrical or
mechanical improvement, or where a material is replaced with a safer alternative (such as the removal
of asbestos based components). In these cases, the mechanical performance, such as the ability for
the copper to move freely in the slot, may be altered and create new problems for the operation of the
rotor.
Many issues have been discovered on generator rotors, either in the balance facility or when the rotor
is installed and being recommissioned at site, such as:
 High running vibration
 High thermal response (change in vibration between different operational loads)
 Earth faults
 Unacceptable interturn defects.
These are easier to investigate and usually quicker to resolve while they are still within the workshop
and/or before the rotor has been installed and the turbine-generator has been rebuilt.

Figure 3-1 - heavily contaminated rotor endwinding

There are three main problems which may occur in a rotor insulation system:

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

3.1.1 Rotor Ground Fault

This is where there is a connection from the copper winding to the ground of the forging. This can occur
where:
3.1.1.1 Contamination has bridged between the copper to the forging
This is most likely to occur at the slot exits at the end of the active part of the rotor. However, it also may
occur throughout the coil, where there are relatively small creepage paths from the copper to the steel,
such as any ventilation slots, either at the bottom of the coil, or close to the wedges at the top of the
slot.
3.1.1.2 The insulation between the copper and the steel has moved.
An example of this is where the slot liners have ratcheted to a new position, leaving a clear path between
the copper and the steel.
3.1.1.3 The insulation between the copper and the steel has been compromised.
Examples of this might be where the insulation has been fretted away (such as on turning gear, or
through heavy cycling), or where foreign objects, or a sharp part of the copper has pressed, under high
centrifugal forces, through the insulation.
It should be noted that a rotor can be operated with a single ground fault. If there is only one ground
fault, there will be no circuit and no destructive current will flow. However, this is not recommended, and
indeed many protection systems will trip on single rotor ground fault. Although some will allow a limited
time to investigate (for example if there is contamination of the brushgear).
If the rotor experiences two or more ground faults, there is a high potential for large currents to flow
destructively through the rotor forging and cause violent vibrations. This can cause irreparable damage
to the rotor components.

3.1.2 Rotor Interturn Faults

More common electrical rotor faults are interturn faults (sometimes called a turn to turn short). These
are where there is a break in the insulation between turns of the copper coil. These are generally caused
by insulation movement/cracking, insulation being punctured or contamination; either from external
sources (more likely on air-cooled generators) or copper dust created by copper abrading when on
turning gear operation.
Interturn faults are frequently not operationally significant and in fact, many generators operate for many
years with little problems. However, it can be indicative of a general degradation of the rotor insulation
as it gets older, or bulk contamination of the rotor winding.
An interturn fault will do two things, firstly if the rotor current bypasses one turn of the rotor, then there
will be less magnetomotive force (mmf) created (related to amps*turns) and lead to a slight drop in the
generator stator voltage. This will be detected and the AVR will feed more current into the rotor. Although
this effect will be slight, as more interturn faults occur, the more current is required to compensate. If
enough interturn faults exist, and the excitation current requirement rises beyond the limit of the AVR
and/or excitation system, the reactive power (and eventually the real power) output will be limited.
Secondly, if a turn is being bypassed, it will be generating less heat as less current flows through it.
There will, therefore, be one coils less heat in one pole of the generator winding than the other. The
cooler pole will not expand as much as the other, and the rotor will bend slightly. This bend will cause
the centre of mass to shift away from the shaft centre and cause elevated rotor vibration.
At the fault, there will usually be some localised heating due to the poor quality of the electrical
connection. This can lead to further degradation.
The severity of interturn faults will depend on its position in the winding, and the winding design. If there
is an interturn fault between two turns in a stack of 22, it will not be as much of an issue if it is a fault
between two turns in a stack of 8 turns. Also, if there is an interturn fault on the shorter coils nearer the
pole, this will create a more localised cold spot, this will have a greater propensity to lead to vibration
problems.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

Figure 3-2 - Endwinding insulation which has had a Figure 3-3 - Damage to slot liner through wear
hole burnt through it causing a ground fault.

Figure 3-4 - Damage to slot liner through wear

Figure 3-5 - Migration of turn insulation

Figure 3-6 - Migration of slot liner insulation (copper will have been uninsulated at the other end)

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

3.1.3 Intercoil and Interpole Faults

Intercoil (coil to coil short) and Interpole (pole to pole shorts) faults can have a much more severe
outcome than interturn faults. An Interpole fault happens in the endwinding either where the copper has
distorted out of shape and comes into contact with its neighbour or contamination of the winding allows
a connection between two coils. It is possible that the effect can be minimal if the two coils are at the
same end as the coil-coil connection, as there will be only one turn shorted out. However, if it is the
opposite side to the connection, it will short out almost two full coils.
If the fault is at the top turns (the closest to the retaining rings), it is possible that the fault will generate
heat which could burn through the retaining ring insulation and cause a rotor ground fault.
An interpole fault is more severe still and could short out almost all turns of the entire winding.
In both cases, with the exception of the intercoil fault which only shorts out a turn, it is unlikely that a
generator would continue operation with either high vibration, rotor ground fault, loss of field or another
AVR fault causing a trip or the operator tripping the machine.
It is unlikely that a pole-pole or coil-coil fault would occur following maintenance as they are usually
associated with longer term operation or contamination.

Figure 3-7 - Intercoil short due to contamination on

the endwinding

Figure 3-8 - Intercoil fault due to copper

deformation

3.1.4 Preventing Electrical Problems

Much of the above can be mitigated by using a competent service provider with an excellent quality
(QA/QC) and clean conditions (foreign material exclusion) procedures.
Service providers must be fastidious in recording the disassembly to ensure that nothing is missed on
reassembly. Even if the rotor is of a common type, it is possible that there may be small design
differences which can catch out even the most experienced winders.
Rewind facilities should be clean and well organised with access limited to the rotor. Some of the better
winding facilities seen have constant humidity/temperature, positive pressure rooms, with sticky mats at
the entrance to reduce the potential for contaminates to enter the rotor.
It is more difficult to control the access and environment as discussed above if the rotor is worked on at
the site. However, there may be large gains in reducing the downtime if the work is carried out without
taking the rotor offsite. In such a case a risk assessment should be carried out and efforts made to
improve the conditions that the rotor will be worked on.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

When the rotor or any components are not being worked on, they should be protected from damage or
contamination. Once work is finished, the rotor should be quickly packed for transport, or protected if at
site while it is awaiting being fitted. Transport packing varies between heat sealed bags, “dri-clad” bags,
and seaworthy containers, all depending on the journey being undertaken or the time the rotor will be in
storage. Efforts should be made to ensure that the rotor is kept dry (either through desiccant bags or
external dehumidifiers), and leads brought outside the packing to allow insulation resistance checks to
be made on the winding. More information on storage is discussed in the work of Working Group A1.33
- Guide for Cleanliness and Storage of Generators.

3.2 Mechanical
In addition to demonstrating that the residual out of balance is at an acceptable level during high-speed
balancing of the rotor, the stable behaviour of the rotor under operating conditions of temperature and
speed may be important to qualify following repair intervention.
As generator rotor components come under the influence of both centrifugal and thermal expansion
forces during operation, it is possible for the rotor components to move and alter the dynamic
performance of the shaft.
In certain cases, blocked or uneven thermal expansion can occur in both the rotor slot and endwinding
regions which result in imbalance and/or non-uniform dynamic stiffness around the circumference of the
rotor and result in high vibrations for certain operating conditions. This expansion can cause ratcheting
movement of coils and insulation and slip/stick effects where sudden step changes in vibration behaviour
occur when frictional forces are overcome by thermal expansion forces and the expansion is suddenly
released.
These effects may be dependent on centrifugal load and shaft flexural mode shape associated with
rated speed and may not be evident during low-speed balance. The heating effect during operation
should also be replicated as closely as possible, preferably by electrical heating, during balancing.
Further details in the following section.
The shaft flexural mode shape is also related to the structural stiffness of the bearings and foundation.
Some balance facilities will have the ability to simulate the dynamic operating conditions of the rotor
when installed in-situ.
These issues may occur on new or rewound rotors due to design or construction quality issues:
 Material selection of copper/blocking/insulation
 Errors in profile/dimensions of copper turns and end winding blocking and insulation
 Inadequate or incorrectly installed slip planes
 Errors in the installation and finishing of the inter-turn or main wall insulation.
If identified during balancing in certain cases it may be possible to perform corrective action in the factory
to address these causes and improve the rotor performance.
Older rotors, particularly those with high accumulated starts and original copper, may suffer from
distortion of the copper with shortening, lengthening, or axial movement occurring during cyclic
operation. In the case of distorted copper, while high speed balancing may identify the issue, corrective
action may be difficult to resolve. It is recommended to assess the suitability for re-use of the existing
copper when determining repair scope.

3.3 Transport of rotors

Part of the analysis which needs to be considered when deciding on whether or not to send a rotor for
a high-speed test is what risks the transport may introduce. The risks obviously increase with the
distance, borders crossed and the times the rotor is handled (i.e., crane to road transport, road to ship,
ship to road, road to facility).
 Potential for damage to the rotor. There is a risk with handling a rotor for the rotor to get
damaged, either in transport (contamination at sea, vibration from road travel) or through
handling between methods of transport. For example, it has been known for power plant
components to be dropped overboard during offloading from vessels. Damage may be
repairable, however, will add to any business interruption.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

 Unexpected delays. There will always be a risk of unexpected delays in the transport of a rotor
over a long distance. Depending on the geographical location, and time of year, bad weather,
snow, storms can all cause delays. There will also be potential equipment failures to the (often
specialised) truck or ship.
 Delays in Customs. There have been many cases where border crossings have led to long
delays in rotors travelling to/from workshops. Examples have been seen, where customs delays
have added almost two weeks to the program.
 Other Delays in Transport. There can be restrictions for moving large heavy loads within
countries where there are requirements for special permits, road restrictions or police escorts.
These can usually be planned in, but emergent work and delays in program can all lead to long
delays.
Most of the above can be planned in or mitigated through ensuring there is a backup plan if there is a
problem with the rotor.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

4. Maintenance / Repair of Rotors

Generator rotors in theory should require little maintenance. In some modern machines, the OEMs do
not require the rotor to be removed for maintenance within the nominal life span of the power plant. It is
quite possible that within the life of a generator, the rotor may require removal, and work carried out due
to a degradation in the insulation, contamination or on the advice of the OEM.

The work which might be required on a generator rotor can vary from light cleaning of the rotor with the
retaining rings left in situ, to a full rewind with new copper, new retaining rings and repair to the steel
forging. For the purposes of producing the risk matrix (APPENDIX C), the potential work has been split
into defined levels:

4.1 Small repair work with retaining rings left in-situ

This could be where an element of cleaning is required where the retaining rings do not need to be
removed. Alternatively, this could be where there is work on the radial connections and or the slip rings.
By not removing the retaining ring, there will be less of a risk of contamination or insulation movement
caused by the removal and refitting of the retaining ring.

4.2 Small repair / Cleaning with retaining rings removed

This is most likely where there has been a contamination in the rotor, leading to low Insulation
Resistance (IR) or potential interturn faults. The retaining rings have been removed and the source of
the problem can be addressed without removing the winding (or with minimal movement of the winding).
The possibility of introducing a mechanical unbalance in this situation is low as there is little to no change
in the components which might affect balance. There may be a shift in balance if the retaining rings or
fans are refitted incorrectly. This can be mitigated by use of pre and post installation runouts in the lathe.
In most cases, the trim balancing in situ can rectify most problems if found after installation back into
the machine.
An exception may be if the work somehow affected the ability of the slot contents to freely move through
thermal expansion. Alternatively, if some endwinding insulation spacers (“blocking”) are worn and
replaced, the change in mass should be considered.
The chance of introducing electrical issues is slightly higher. If cleaning the endwinding, it is possible to
’push’ some debris in an area which may cause a fault. Also, without proper clean conditions, it might
be possible that foreign objects may enter the endwinding, leading to damage which may only be found
once the rotor is at speed.
Some designs of generator rotor retaining ring require the retaining ring to be “settled” by running at
rated speed or overspeed and then returned to stationary before commencing the balancing operations.

4.3 Rewind using existing copper

During a normal rewind, the retaining rings are removed, then the wedges. The coils are unwound and
cleaned. The rotor forging, retaining rings and wedges are revalidated for future operation. The rotor
coils can then be rewound with new insulation materials. In most cases the blocking system will be
retained unless there is a change of winding resign.
If all the components are put back in the same position (with the exception of the insulation which is
replaced), the chance of having a different balance profile should be minimal. However, it is possible
that several problems might occur:
 Poor clean conditions leading to faults not discovered at low speed
 Insulation not correctly installed leading to faults at speed
 Burrs or similar puncturing through insulation at speed
 Slot liner insulation and top packing strips installed incorrectly restricting thermal expansion
 Incorrect reinstallation of the retaining ring and its insulation.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

The existence of the above cannot be proven until running at speed, and therefore if a high-speed
balance / test is not carried out, the new insulation system should be well designed, and a robust quality
program put in place.

4.4 Rotor rewind with new copper

A rewind with new copper and new insulation material will face the same installation quality risks as
mentioned above. More importantly, the installation of tonnes of new copper, largely by way of a manual
process, will mean that there is a high likelihood the balance could change.

4.5 Repair to forging

Repair to the forging could mean many things. It could be requiring the wedges and/or retaining rings
being removed. As such it is very hard to say at what point the risk of problems has increased.
However, if there is an amount of steel removed (for example a tooth top modification) it is possible that
there will be an impact on the balance of the rotor. If the winding is left in situ, there will also be all the
problems relating to clean conditions, which will be made more difficult to contain if machining operations
are included. If the rotor is rewound, then there will also be all the potential risks as discussed in Section
4.3.
It is possible for repair work on the bearing area of a journal to impact balance, as this can shift the
centre of rotation of the shaft. Methods that do not affect the surface centreline (grinding off a flexible
tool post, honing with a floating set of stones, polishing, etc) would be lower risk.

4.6 New retaining rings fitted

Changing the retaining rings will require the endwinding insulation wrap to be changed and will cause a
disturbance to the endwinding, as such there will be a risk of a disruption causing problems once the
rotor is at speed. But as in all situations, this should be able to be mitigated through good procedures
and competent operators.
The introduction of a new retaining ring should create little disturbance to the balance of the rotor as (if
fitted correctly) it should be naturally balanced by virtue of its design and machining. The integrity of the
ring should be proven by the supplier. However, it is quite normal for operators of plants to want to see
a new retaining ring tested to overspeed in a balance facility before it is run at site.
During worldwide efforts in the 1980s and later to replace 18Mn 5Cr retaining rings to the more resilient
18Mn 18Cr rings, many were changed without high-speed testing with no issues.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

5. High Speed Testing

5.1 High Speed testing facilities
High Speed testing and overspeed testing requires a large facility; usually called a “Balance Pit”,
“Balance Bunker” or “Spin Pit”. The balancing facility will require bearings, a large variable speed drive,
and will be required to contain the debris in the event of a catastrophic mechanical failure at full speed
+20%. This last requirement means that the structure will be large, usually constructed of thick steel
reinforced concrete or thick steel. In some locations they will also have been constructed underground.
Examples of different testing facilities are shown in Figure 5-2 to Figure 5-7
The rotor will need to be heated in order to mimic the changes in temperature which are seen during
operation. Most facilities achieve this by controlling the air flow and allowing the rotor to heat up with the
windage it creates with its fans at speed. However, some will electrically heat the rotor by feeding current
through the windings.
Furthermore, the facility requires the competence to perform the electrical tests and analyse the
vibrational data. As such, the cost of developing a facility can be prohibitive with most balance facilities
being sited next to existing (or ex) manufacturing sites with a few specialised purpose-built service
locations. This means that there are relatively few facilities in the world, generally concentrated in
industrial and post-industrial countries (Europe, Japan, USA, India, and China).
A non-exhaustive list of global balance facilities is given in APPENDIX F. It should be noted that at the
time of writing this report, there is a large amount of change and consolidation in the industry and this
list is currently changing. A map showing their locations is shown below.

Figure 5-1 - Map of the world showing locations of high-speed testing facilities for generator rotors

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

Courtesy of Siemens Energy

Figure 5-2 - Rotor being lowered into a below ground balance facility (300t) with a retractable concrete
roof.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

Courtesy of Siemens Energy

Figure 5-3 - Rotor in a Balance Facility

Courtesy of Siemens Energy

Figure 5-4 - Balance Facility control room

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

Courtesy of Fortum

Figure 5-5 - 30T balance facility

Courtesy of Siemens Energy

Figure 5-6 - 340t high speed balance facility, external view above (with Steam Turbine) and internal below
(with a generator rotor)

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

Courtesy of GE

Figure 5-7 - Balancing Tunnel

5.2 High Speed Testing Process

The process varies from manufacturer to manufacturer or service providers, also depending on what
work is being carried out.
The basic requirements for balancing are covered by ISO 21940-11 [B1] (for rigid rotors) and ISO 21940-
12 [B2] (for flexible shafts). In general, rotors operating below the first critical are considered to be “rigid”.
Rotor’s operating above, or close to the first critical should be considered as being “flexible”. The vast
majority of large generator rotors will be flexible.
For older rotors (built prior to the 1980s) the high-speed balance facility operator may require that the
rotor forging has had its mechanical integrity checked before operating the rotor at overspeed to ensure
that it does not suffer from catastrophic failure. Such checks may include ultrasonic or magnetic particle
inspection of the forging, if the rotor has a bore, a boresonic inspection may also be required. Such
testing may require the rotor to be partially or completely rewound.
An example of the work scope that may be expected if it is decided to carry out a high-speed balance
and test are given below:

5.2.1 Concentricity Checks

These are carried out, usually with the rotor in a lathe or in the balance facility, to establish the
concentricity of the Journals, Couplings, Retaining Rings and Rotor Body.

5.2.2 Pre-Balance Electrical Testing

An initial IR (Insulation Resistance), PI (Polarisation Index) and RSO (Recurrent Surge Oscillograph)
would usually be carried out at this stage at zero speed.

5.2.3 Preliminary Balancing

The rotor will be run up at an ambient temperature, measuring the vibrations. Balance weights will be
added or removed to improve the balance across the speed range, ensuring that the rotor is within the
specified limits, throughout all critical speeds to rated speed and possibly at 10% overspeed.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

The process will be iterative, and several runs may be required to find the best balance weight
distribution. Once the rotor balance is within the required standards, a further run would be carried out
to prove the stability and repeatability of the readings.

5.2.4 Heat Run

With an acceptable balance across the speed range (as above) the rotor will be taken to rated speed
and heated up to near operating temperature. This will either be through windage caused by spinning
the rotor or through electrical heating (using the rotor’s sliprings).
It is largely considered that heating the rotor with direct current injection is a better method of testing at
speed as this will provide a closer representation of how the rotor will respond in normal operation i.e.,
the heat is created in the copper, causing the rotor winding to thermally expand quicker relative to the
steel forging. However, there is considerable capital investment required to build a balance facility which
can supply the power required to heat the rotor as well as having the civil structure able to deal with
induced voltages and currents from the rotating magnetic field created.
In some cases, existing balance facilities can add a flux shield to protect surrounding metal pipes and
metal rebar from such magnetic fields.
The change in vibration (vectoral and absolute) is monitored through the speed range to ensure that
there are no significant issues with large vector changes and the rotor stays within the limits specified
in the standards (or specifications).
Once the rotor has been heat soaked at the required temperature, it should be run down to turning gear
speed and back to operating speed.
The thermal response is the first shaft order vectoral change in the vibration from cold to hot conditions.
A thermally stable rotor will see a change of less than 25%, however, higher values may be acceptable.
Some manufacturers specify a maximum vector change of 3 mils (76µm) from cold to hot or hot to cold.
The definition of the hot and cold temperature can vary but “hot” would be high enough to simulate near
operating conditions. A temperature change and vibration readings at 20°C (cold) to 85°C (hot) is not
unusual.
Again, the process may require further heat runs to iteratively add/remove balance weights to improve
the thermal response.
Concentricity’s would normally be rechecked following the heat runs.

5.2.5 Overspeed
For new machines, the rotor would be overspeed for 2 minutes to a value of 120% rated speed (usually
in the hot condition). For refurbished rotors, this value is generally less at 110% for 1 minute. Further
details can be seen in IEC 60034-1 [B3] and IEC60034-3 [B4].
This is largely to ensure that the vibration is still acceptable throughout overspeed operation following a
turbine trip, but also to prove the mechanical integrity of the rotor.
Following run down, concentricity would be rechecked and compared with the initial results.

5.2.6 Acceptance Run

This is a final proving of the rotor from 0 RPM to full speed (or to 110%) to show that nothing has
changed following the overspeed. This may be a chance to add any trim balance weights to the rotor to
improve the absolute shaft displacement.
Different acceptance criteria exist. ISO 21940-11 [B1], for rigid rotors, defines criteria on residual
unbalance. For flexible rotors, ISO 21940-12 [B2] defines criteria on vibration on the bearing pedestal
calculated from permissible bearing vibration on site and also shaft vibration calculated from the
permissible shaft vibration on site. A formula gives an equivalence between criteria on site and in the
balancing facility. Vibration level measured on site and in the balancing facility can be very different (up
to x5), depending on the characteristics of the bearings and couplings. The service provider should
produce a calculation note justifying the criteria to be taken into account and explaining the

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

characteristics of the bearings used in the balancing facility and how to get the equivalence with vibration
level on site.
Details of electrical testing which would normally be carried out is discussed further in 5.3
The concentricity’s would then be rechecked, and the retaining rings checked to see if they have settled
(dependent on the design).
An inspection should be carried out of the rotor to ensure that the endwindings have not suffered
movement or damage, and that all the balance weights are securely fastened.

5.3 Electrical testing at speed

Testing at rated speed in the balance facility allows the operational conditions a rotor experiences in
service e.g., centrifugal forces and to some degree operational temperatures to be replicated in a
controlled environment. The testing techniques are designed to prove the main slot and inter-turn
insulation systems behave in an adequate and predictable manner for reliable operation in service.
Connection to the winding is made though brushgear / slip rings of the rotor or an additional slip ring
shaft for brushless designs.
If electrical testing is not performed at speed in a balance facility, there is a risk that assembly or
performance defects will not be identified before the rotor goes into operational service. A suite of
electrical tests accompanies the mechanical balance operations and thermal assessment in assessing
the rotors overall fitness for service.
A typical scope of electrical testing comprises:
 Winding Insulation Resistance (IR)
 Winding Recurrent Surge Oscillograph (RSO)
 Winding Withstand Test
 Air Gap Search Coil (AGSC or Flux Probe) Analysis
 Pole Drop Test
 Winding Impedance Test

5.3.1 Winding Insulation Resistance

A relatively simple test that can be performed with the rotor stationary and at rated speed. A DC test
voltage is chosen according to the rating of the winding. The test assesses the effectiveness of the
ground insulation e.g., slot liners, retaining ring liners against faults and the suitability of the winding for
further high voltage withstand testing e.g., at power frequency or DC.
Further details of the insulation resistance test are covered by IEEE 43 [B5].

5.3.2 Winding Recurrent Surge Oscillograph (RSO)

A simple and very sensitive test based on the principles of time domain reflectometry. The test identifies
defects in the main slot or inter-turn insulation systems by comparison of a reflected step (square) wave
sent from both ends of the winding in succession. When the responses from each pole are overlaid, if
they are perfectly superimposed this would indicate no winding insulation defects. A separation in the
overlaid responses can indicate a winding defect, the location of which can be mathematically
calculated.
The RSO is a very sensitive test and can detect faults which might not be current carrying in service. It
cannot distinguish between a current carrying defect (shorted turn) and one which does not. The latter
will not introduce an immediate problem for the winding, but it does reveal a weakness which may
develop over time. It is a useful test in both immediate assessment of a winding insulation system and
long-term trending of the insulation systems performance. “Fingerprint” RSO tests performed at rated
speed are particularly useful in allowing long term condition monitoring of a rotor winding. The test is
most beneficial for 2 pole windings but is effective for 4 pole or multipole windings.
The acceptance criteria for RSO are usually no indications found. However, this is a strict requirement
and can be difficult for some service providers to achieve, especially if testing is being carried after work
which did not include a rewind.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

It is important to note that an RSO indication may not be a current carrying shorted turn, and that a
current carrying shorted turn may not affect operation.

Indication of a fault

Figure 5-8 - example of an RSO plot showing a fault. In a fault free rotor, the red and blue traces would
overlap

5.3.3 Winding Withstand Test

Sometimes referred to as HV test, Pressure Test or “Hi Pot” test. This test subjects the winding to a
short duration e.g., 1 minute, overvoltage to prove the resilience of the ground insulation. It is commonly
performed with the rotor stationary then at rated speed. International standards give guidance for test
voltages and most OEMs have their own guidelines. Testing can be performed at power frequency or
DC. As asset owners, caution should always be exercised in selecting the test voltage. The value should
reflect the age (or possibly mixture of ages) of ground insulation in the winding. Derating factors can be
applied to arrive at a suitable test voltage balanced between proving the rotor fit for service and not
causing undue stress to existing components. The test is generally only performed following invasive
works to the winding e.g., rewind, partial rewind, replacement of retaining ring insulation or if the winding
insulation has been mechanically stressed during works in the factory.
Further details of the high voltage test can be found in IEEE 95 [B6] which also suggests test voltages,
however, caution may be applied on older or contaminated rotor windings. The withstand test is a
pass/fail test. If the winding withstands the test, it is ok, if it fails, the rotor will have to be dismantled for
repair. As such, the owner should always be aware, that if carrying out this test, there is a chance the
rotor might fail, and if it fails, it may be not be able to be returned to service. The other viewpoint would
be that if the rotor was tested and it fails, it is quicker to address the issues at a workshop, rather than
if it was installed in a generator.

5.3.4 Air Gap Search Coil (AGSC or Flux Probe) Analysis

The balance facility must have the ability to inject current into the rotating winding via the slip rings in
order to perform this test. Rated current is not generally required; a few tens of amps is sufficient. It is
identical to the analysis performed from air gap search coils or flux probes installed within operational
units with the exception that measurements are made by applying current in both directions in a balance
facility. The test identifies inter-turn insulation faults (shorted turns) but not ground faults by comparison
of the voltage signals produced from the leakage flux across opposite slots in the winding e.g., B coil of
Pole 1 compared to Pole 2. A shaft marker signal is required to identify which pole is which from the

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

signal returned by the search coil. The test can also be easily performed on multi-pole machines. False
indications are possible where there are components in the slot with magnetic properties, such as steel
wedges.

Figure 5-9 - Example of a flux probe test. The two waves should overlay. Any difference is given on the
blue "null" trace and can indicate a shorted turn

5.3.5 Pole Drop Test

Typically, a test performed in the field for stationary rotors however can be applied at a balance facility
to identify crudely if the winding contains shorted turns or ground faults. The ability to inject current into
the rotating winding and accurately remotely measure the voltage developed across each slip ring to
the pole-to-pole connector and between slip rings is required. Balanced slip ring to pole to pole
connector voltages indicate no current carrying faults (shorted turns) are present within the winding.
Unbalanced measurements can indicate a difference in brush to slip ring contact or a winding shorted
turn, the location of which can easily be approximated by evaluation of the three measurements.

5.3.6 Winding Impedance Test

The balance facility must have the ability to inject AC current into the rotating winding and accurately
remotely measure the voltage developed across the slip rings in order to perform the test. Current is
injected into the winding with the speed of the rotor gradually increased to rated speed. Rotational speed
is held at e.g., 200 revs/min steps to allow voltage and current measurements to calculate the winding
impedance. The test is repeated during the deceleration of the rotor to turning gear speed or stationary.
A smooth linear response in plotted impedance with speed indicates a winding with no shorted turns. A
sudden change in impedance can indicate the presence of a shorted turn within the winding insulation
system.

Although this test is usually carried out with power frequency AC, some manufacturers use a higher
frequency for a greater resolution.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

5.4 Testing of brushless rotors

Brushless rotors present a challenge to testing at speed as, by their nature they have no connections
for carrying out electrical testing at speed. Furthermore, depending on the configuration, thermal testing
at speed may also be a problem.
In some cases, a stub shaft with slip rings can be connected to the rotor shaft to facilitate such testing
at speed. If no such shaft is available to connect to the rotor then the electrical testing is restricted to
what can be carried out at standstill.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

6. Results of questionnaire
As part of the research for this working group, we created a questionnaire to survey the tests which were
specified by various users, OEMs and service providers and also what experiences they had with
carrying out repairs on generator rotors and whether any problems had occurred.

Our questionnaire asked the following questions:

1) Describe your business (OEM / 3rd Party Supplier / Operator)

2) At what point would you normally consider work on a rotor would require in works high speed
mechanical and electrical testing.
a) If the end rings are removed (Y/N)
b) If work is carried out on the blocking in the end windings (Y/N)
c) If any light mechanical work is carried out (Y/N)
d) If the rotor is rewound using existing copper (Y/N)
e) If the rotor is rewound with new copper(Y/N)
f) If there is large mechanical work carried out. (Y/N)
g) If the end rings are replaced (Y/N)
h) If the wedges are replaced. (Y/N)
3) Would you require all high stress mechanical components (retaining rings, rotor fans, wedges)
to have undergone a high-speed test in a high-speed facility before you would fit them into your
generator?
4) Do you have experiences where you have opted not to have in works high speed balance during
repair works and the rotor is un-runnable due to high vibrations or suffering from high vibrations
due to a mechanical issue? (please give details)
5) Do you have experiences where you have opted not to have in works high speed testing where
the rotor is un-runnable due to electrical problems in service? (interturn faults / earth fault etc)
6) Which high speed balance facilities have you used?
7) What electrical tests do you specify following rotor repair? (yes / no)
a) IR test
b) IR test at Speed
c) RSO
d) RSO at Speed
e) Air Gar Search Coil
f) HIPOT
g) HIPOT at speed
h) Polarisation Index
i) Polarisation Index at Speed
j) Winding Resistance
k) Rotor Impedance
l) Rotor Impedance at Speed
m) Other (Please Specify)
8) What is your preferred method of heating the rotor (for example current injection or windage
heating)

The full answers are available in APPENDIX D, but a summary of the results is:
1) We had twelve responses. One consultant (USA), one OEM (UK), two service providers
(Sweden and Romania), and eight operators (UK, Netherlands, Egypt, France, Brazil, Eire,
Spain)
2) The following chart shows whether the respondents would normally carry out high speed testing
for the various scenarios.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

14

12

10

Yes No

3) When asked whether high stress components (such as retaining rings and wedges) would be
tested before use, six respondents replied with yes, and seven said no.
4) When asked about whether they had experience of not carrying out high speed testing and
having mechanical and electrical problems (question 5) the responses were fairly mixed
between them being “rare” to individual examples of problems.
5) As above
6) Provided us with further information to use in our list of international high speed testing facilities.
7) The tests specified during testing by the respondents is shown as below.

12

10

Yes No

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

8) When asked about the preferred method of heating rotors, the general consensus was heating
by current injection was preferable.
We also asked for examples of rotor work which is included in APPENDIX E which provided the
experience used in this document.

Unfortunately, we had a low number of respondents to the questionnaire, furthermore, most were in
Europe. We had no response from any operators in north America, Asia, or Oceania. As such, most
answers are provided from operators with ready access to high-speed facilities within a few hundred
kilometres.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

7. Summary
The lowest risk option is considered to be to have the rotor tested for electrical integrity and balance at
a high-speed balance facility. However, due to commercial pressures it may be required to forego
such testing following maintenance on the rotor.
High speed balancing and overspeed testing has several benefits:
1) To check the mechanical integrity at working speed plus a margin of safety, to reduce the
likelihood of a large mechanical failure at site
2) To record the vibrational footprint of the rotor from standstill to full speed (plus overspeed)
3) To record the vibrational footprint of the rotor from ambient conditions to working temperature
(or near to) through windage or current injection.
4) To ensure that the rotor is thermally stable, and the thermal response is repeatable.
5) Work to optimise the vibrational performance across speeds and temperatures through the
addition of weights (“balancing”)
6) Perform electrical tests at full rated operational speeds.
7) To “settle” the endwinding retaining ring and other shrunk-on components above normal
expected operating speed, if required.
8) To validate the electrical integrity of the insulation following mechanical stress from centrifugal
loading and thermal expansion.
9) To reduce the need for in-situ or trim balancing runs on site that may delay the return to
service.

Due to the relatively difficult access to a balance facility, the potential transport difficulties (distance,
handling, and customs implications), the cost of the testing and the time taken for the work, there can
be a compelling financial argument to avoid such tests.
Low speed balancing will help to mitigate some of the balance problems. However, it will not be able to
show how the rotor changes thermally or test the insulation under the pressures of centrifugal forces.
Low speed balancing would not be recommended for rotors operating near a third critical as this will be
a poor reflection of the balance state at rated speed. Low speed balance results can provide a false
sense of security that the rotor is successfully balanced at rated speed.
It is considered that large 2-pole rotors are generally at a higher risk than 4-pole rotors of balance
problems being undiscovered if high speed testing is not carried out. This is largely related to the fact
that most large 4 pole rotors are less flexible, i.e., they are operated between the 1st and 2nd critical
speeds, whereas the 2 pole rotors operate between the 2nd and 3rd critical. However, 4-pole rotors are
mostly used on nuclear plants which may have a different cost/risk attitude to conventional plants.

7.1 Potential problems

If the decision is made not to carry out a high-speed balance along with electrical and overspeed testing,
there are several potential problems which may occur.
 The rotor is returned to service and experiences high vibration issues which could have been
addressed through balancing. In some cases, these can be addressed with “trim” balancing on
the rotor or even the turbine or exciter. But there is potential that the rotor will require
removing from the generator and returning to a workshop.
 The rotor is affected by an electrical fault at speed. This could be anything from a small non-
current carrying interturn fault discovered through an RSO test to a ground fault. A current
carrying interturn fault may lead to a thermal driven vibration issue which may not affect
operation, or it may be required to be addressed with a balance in-situ. However, in extreme
cases may lead to operational restrictions on load (real, reactive or both). In the event of a
ground fault developing at speed, it is recommended that the rotor is not run and returned to
works for repair.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

 Rotor experiences thermal driven vibration due to sources other than an interturn fault.
Possible causes include but are not limited to; incorrect endwinding blocking, obstructed
ventilation, tight slot build, etc.
 Catastrophic failure of a mechanical component. This is a very rare occurrence and all new
mechanical components (such as forgings, retaining rings and wedges) should be thoroughly
tested for mechanical integrity before installation.

7.2 Considerations
There are several factors which need to be considered of when deciding about the level of risk involved
with choosing not to carry out a high-speed test / balance
 How flexible is the rotor (slimness factor: diameter/length)? Is its running speed above the 1st
and 2nd critical?
 What is the accessibility of local balance facilities?
 Is it possible to trim balance on site (do you have access to balance planes easily?)
 Is it possible to carry out trim balances on generators which are used as a motor to start the
gas turbine?
 Does the design require an overspeed to “settle” the endwindings or endwinding retaining
rings?
 How experienced are your service providers in successfully rewinding rotors? Do they have
experience in the specific design of your rotor?
An additional consideration that should be stated is that high speed testing is not always a guarantee
that no balancing will be required on start-up at site. There are factors from assembly (such as the
coupling bolt residual balance, runout of rabbet fits and relative alignment of mating shafts, etc) that
could introduce an imbalance at assembly. Almost always these sources of imbalance can be addressed
with a “trim”, as the imbalance is not in the bearing span of the generator rotor, but external to the
machine.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

APPENDIX A. Definitions, abbreviations and

symbols
A.1. General terms

App Table A.1 Definition of general terms used in this TB

Acronym Phrase Definition

TB Technical Brochure A publication produced by CIGRÉ representing the
state-of-the-art guidelines and recommendations
produced by an SC WG. Individual Members, or staff
of a Collective Member can download the PDF for
free using their login credentials (copyright
restrictions for use within their own CIGRE
Membership only)
SC Study Committee One of the 16 technical domain groups of CIGRE
WG Working Group A group formed by a SC to develop a TB on a
particular subject of interest

A.2. Specific terms

To assist with understanding, this paper is written with the following terms:
 “Rotor” describing the rotating component of the generator which supplies the magnetic field
which excites the generator stator. Sometimes known as the “Field”
 “Ground” is used over “earth”. For example, a fault from the copper conductors to a grounded
or earthed component (such as the rotor forging) is referred to as a “ground fault”
 “Turning” – slow speed turning of the turbine generator rotor when not in operation, also
known as “barring”.
 “Balance Facility” is used in preference over other various terms such as “spin pit”, “balance
pit”, “balance tunnel” or “balance bunker”.
 “Retaining Rings” or “Endwinding Retaining Rings” is used to describe the shrunk-on steel ring
which holds the rotor endwinding in place at speed. These are also known as “end rings” “end
bells” etc.
 “Sliprings” is used over “collectors” to describe the rings on the rotor where current is fed from
the brushgear.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

APPENDIX B. Links and references

[B1] ISO 21940-11, Mechanical vibration – Rotor balancing – Part 11: Procedures and
tolerances for rotors with rigid behaviour
[B2] ISO 21940-12, Mechanical vibration – Rotor balancing – Part 12: Procedures and
tolerances for rotors with flexible behaviour
[B3] IEC 60034-1, Rotating electrical machines – Part 1: Rating and performance
[B4] IEC 60034-3, Rotating electrical machines – Part 3: Specific requirements for synchronous
generators driven by steam turbines or combustion gas turbines and for synchronous
compensators
[B5] IEEE Std 43: IEEE Recommended Practice for Testing Insulation Resistance of Electric
Machinery
[B6] IEEE Std 95: IEEE Recommended Practice for Insulation Testing of AC Electric Machinery
(2300 V and Above) With High Direct Voltage

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

APPENDIX C. Risk matrix

Risk of problems undetected if there is no high-speed testing
Work Carried out Mechanical Catastrophic Failure Notes
Unbalance
(wedge/ring
liberation)
Small repair work with retaining rings left Very Low Risk Very Low Risk Very Low Risk
in situ
Small repair / Cleaning work with Low-Medium Risk Low-Medium Risk Very Low Risk
retaining rings removed
Rewind using Existing copper –blocking Medium Risk Medium Risk Very Low Risk
design original
Decontamination of rotor (without Medium Risk Medium Risk Very Low Risk Depending on the initial condition. If there is
rewind) heavy contamination, a rewind may be a
preferred option.
Rotor Rewind with new copper Higher risk Medium Risk Very Low Risk
Repair to forging Medium Risk Medium Risk Very Low Risk Depending on the extent of the problem
New Retaining Rings Fitted Medium Risk Medium risk Very Low Risk As long as the new components have been
tested and validated
New Wedges Fitted Medium Risk Medium Risk Very Low Risk As long as the new components have been
tested and validated

As a guidance
High risk would constitute an issue in more than 1 in 5 instances.
Medium risk would have an issue which cannot be dealt with on site (such as trim balance) around 1in 10 to 1in 50 instances
Low Risk you would expect an issue in less than 1 in 100 instances

Matrix is for 2 pole machines. 4 pole rotors would be less risk for mechanical unbalance.

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

APPENDIX D. Questionnaire responses – testing

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TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

APPENDIX E. Questionnaire – experience on

rewinds

Key to the questionnaire date:

*2. Balance method
*1. Work carried out N: no balancing
Description Code T: only trim balancing

small repair work with retaining ring a L: low speed balancing with option to trim
balancing
and slip ring left in situ (for example
to change sealing ring of radial H: High Speed balance with overspeed.
connection or to change plate in
centre bore

Small repair To change end B1 *3. Results

work with packing or insulation A. No Issues
retaining B. Rotor required further in situ balancing
To repair work of B2
ring C. Rotor has higher vibrations than
interturn insulation of expected.
removed
end D. Rotor was removed due to high vibration
E. Rotor was removed due to electrical fault
Decontamination of B3
(Ground Fault or large Interturn fault)
rotor with wedge
F. Rotor has electrical fault (interturn) but is
removed runnable.
Rotor rewind with old copper and C G. Other (please describe the detail in notes
retaining ring

rotor rewind with new copper D

To change retaining ring E

To change wedge F

Repair to forging with grinder G

repair to forging with welding H

repaired

To change slipring I

To change field lead or interpolar J

connection

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TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

APPENDIX F. List of high-speed balance facilities of

more than approx. 25T capacity
Country City Company Description

Australia Geelong Bob White Electrix 85T maximum, up to 3600RPM (part of

ABB)
Austria Weiz Andritz Hydro 200T maximum, up to 4500rpm, Air
facility
Belgium Charleroi GE Ex-ACEC works 250t Atmospheric
Belgium Antwerp MHI 100T HSB
Brazil Jundiai Siemens
China Jinan Jinan Electric Power 80t Vacuum
Equipment Factory
China Deyang City Dongfang Electric 350T Air facility
China Harbin Harbin Electric 200T
China Shanghai Shanghai electric 386T Vacuum pit
China Shanghai Shanghai Electric 232T air chamber
Czech Plzen Brush Ex-Skoda works, 2 pits, 80T 4500rpm
Republic
France Belfort GE 250t Vacuum
Germany Muelheim Siemens 340T Vacuum pit,
Germany Muelheim Siemens 66T
Germany Muelheim Siemens 72.6T
Germany Muelheim Siemens In construction
Germany Manheim GE
Germany Berlin GE
Germany Berlin GE 125t Vacuum
Germany Essen Siemens 66T
Germany Essen Siemens 44T
Germany Erfurt Siemens 88T Vacuum
Germany Erfurt Siemens 64T
Germany Berlin Siemens 138T Vacuum
Germany Berlin Siemens 66T
India unknown BHEL
India Sanand GE 125t Vacuum
India Baroda GE 50t Vacuum
(Vadodara)???
India Hyderabad Siemens 88T
India Chennai Toshiba
India Hazira L&T MHPS Website:
https://www.lntmhpsturbogen.com/
Address: Hazira, Surat, India
Facility: HSB Test facility DH10
Capacity: Max Diameter of rotor 4.2
meters
Max weight – 125 tons
Max length – 22 meters (rotor
length 17 meter)
Max rpm – 4500

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 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

India Bengaluru Triveni Turbines Website:

https://www.triveniturbines.com/
Address: Bengaluru, India
Facility: HSB Test facility DH-9
Capacity: Max Diameter of rotor 4.7
meters
Max weight – 58 tons (Need
to reconfirm with facility)
Max length – 12 meters
Max rpm – 8000
Max journal – 475 mm
Italy Genoa Ansaldo 180T – high level of vacuum
Italy Genoa Ansaldo 100T – hot balancing – up to 4320 rpm
Japan Kobe MELCO
Japan Yokohama Toshiba
Japan Hitachi City Hitachi
Mexico Nuevo Leon / GE 55t Vacuum
Morelia
Poland Lubliniec Ethos 80T
Poland Wroclaw GE Atmospheric 70t
Poland Elblag GE 80t Vacuum
Romania Bucharest General Turbo / GE 220T Vacuum
Russian St Petersburg Electrosila
Federation
Saudi Arabia Al Khobar Siemens 50
Saudi Arabia Dammam Siemens ISCOSA workshop
South Africa Johannesburg Rotek (Eskom) 300T 3600RPM, current injection.
Sweden Vasteras Fortum 30-110T, up to 4320RPM heat run with
current possible at high speed
Sweden Vasteras Fortum 30T, up to 4320RPM heat run with
current possible at low speeds only.
Switzerland Birr GE 1 Turbo- and 1 Vacuum- facility both
with current injection
UAE Jebel Ali (Dubai) GE Service Centre – 55T Atmospheric.
12.3M maximum length.
UAE Abu Dhabi MHI 100T HSB
UK Newcastle Siemens 200T CA Parsons Works,
UK Newcastle Siemens 99T
UK Rugby GE 160T Vacuum
UK Birmingham Sulzer 13m, 50T up to 5200rpm
USA Houston, TX Siemens 25T Vacuum
USA Charlotte Siemens 250T
USA Charlotte Siemens 365T Vacuum
USA Charlotte Siemens 50T
USA Charlotte Siemens 40T
USA Schenectady GE Steam / Gen Factory – 2 pits. 210MT
max weight. 18m max bearing
centreline length. 4320 RPM. Heating
through current injection. Vacuum.

USA Chattanooga GE Manufacturing

USA Richmond GE 350 Vacuum
USA Houston Sulzer 9m, 25T (Vacuum Chamber)
USA ? Elliot 9m, 20T
USA St Louis MD&A 90T, current injection
USA Milwaukee Toshiba Ex Allis Chalmers facility

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 ISBN : 978-2-85873-583-9

TECHNICAL BROCHURES
©2022 - CIGRE
Reference 878 - August 2022
 TB 878 - Guidance on High Speed Testing of Turbo Generator Rotors

USA Brownsville NEC Up to 100T, 4320 rpm

USA New Mexico Ethos 50T
USA Savannah MHPS
USA Pittsburgh Brush 50T, 4500rpm, 13m

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