IEEE Transactions on Energy Conversion, Vol. 3, No.

3, September 1988 607

THE IMPORTANCE OF GROUNDING BRUSHES TO THE SAFE OPERATION OF LARGE TURBINE GENERATORS

G. W. B u c k l e y R. 3. C o r k i n s R. N. Stephens
Member, I E E E Member, IEEE

The D e t r o i t Edison Company

2000 Second Avenue
D e t r o i t , Michigan 48228

A b s t r a c t - F o u r s o u r c e s o f v o l t a g e on t h e s h a f t s SOURCES OF SHAFT POTENTIAL

o f l a r g e t u r b i n e g e n e r a t o r s a r e i d e n t i f i e d . Tech-
n i q u e s f o r measuring t h e s e v o l t a g e s a r e o u t l i n e d . The T h e r e a r e t h r e e p r i m a r y p o t e n t i a l sources o f
consequences o f n o t p r o v i d i n g e f f e c t i v e s h a f t g r o u n d - s h a f t v o l t a g e s o n t u r b i n e g e n e r a t o r s h a f t s and o n e
i n g b r u s h e s t o r e d u c e s h a f t p o t e n t i a l , t h e magnitude s e c o n d a r y s o u r c e t h a t may o r may n o t b e i m p o r t a n t i n
o f s h a f t p o t e n t i a l s , and s p e c i f i c components w h i c h a r e s p e c i f i c cases. These sources a r e :
a t r i s k a r e discussed. Recommendations f o r b a s i c
i n s t a l l a t i o n and m a i n t e n a n c e p r o c e d u r e s f o r s h a f t 1. S h a f t v o l t a g e s g e n e r a t e d b y charge separation i n
g r o u n d i n g b r u s h e s a r e made. F i n a l l y two r e c e n t t h e l a t t e r stages o f t h e steam t u r b i n e .
unusual e x p e r i e n c e s a t t r i b u t e d t o g r o u n d i n g b r u s h e s 2. Capacitive coupling of the excitation control
a r e discussed. system r i p p l e v o l t a g e w i t h t h e s h a f t .
3. G e n e r a t i o n o f a s h a f t v o l t a g e b y an asymmetrical
INTRODUCTION generator airgap o r s t a t o r f i e l d w h i c h l i n k s w i t h
the r o t o r shaft.
S h a f t g r o u n d i n g brushes a r e used on l a r g e t u r b i n e 4. S t r e s s i n g o f t h e t u r b i n e s t a t i o n a r y and r o t a t i n g
g e n e r a t o r s t o p r e v e n t b u i l d up o f e l e c t r i c a l c h a r g e o n blades/nozzles o r buckets causes t h e b l a d e s t o
t h e s h a f t . The e l e c t r i c a l charge r a i s e s t h e p o t e n t i a l become m a g n e t i z e d b y m a g n e t o s t r i c t i o n , w h i c h on
o f t h e s h a f t r e l a t i v e t o t h e casing. I f t h e p o t e n t i a l r o t a t i o n , g e n e r a t e s a s m a l l a.c. v o l t a g e a c r o s s
i s allowed t o b u i l d t o o high, i t w i l l discharge t o the turbine.
ground wherever t h e gap i s t h e s m a l l e s t . Those compo-
n e n t s w h i c h a r e m o s t v u l n e r a b l e t o damage a r e t h o s e Charge S e p a r a t i o n
w i t h t h e s m a l l e s t c l e a r a n c e s s u c h a s t h e o i l pump
b e a r i n g s , h y d r o g e n s e a l s , o r t h e governor s h a f t b e a r - Charge separation i s usually greatest i n the
i n g s . The g r o u n d i n g brushes l i m i t t h e v o l t a g e t o s a f e l a t t e r s t a g e s o f t h e t u r b i n e where t h e steam i s no
l e v e l s b y p r o v i d i n g a p a t h f o r i t s d i s c h a r g e . When l o n g e r s u p e r h e a t e d Cl]. The a c t i o n o f t h e wet steam
t h e t u r b i n e generator s h a f t v o l t a g e i s measured w i t h - b r u s h i n g p a s t t h e b l a d i n g causes t h e b l a d e s t o p i c k u p
o u t t h e brushes i n s e r v i c e i t d i s p l a y s t h e t y p i c a l e l e c t r o n s and a c q u i r e a n e g a t i v e charge and hence v o l t -
shape o f a c a p a c i t o r c h a r g i n g and t h e n d i s c h a r g i n g . age. T h i s e f f e c t i s a l s o seen t o a l e s s e r d e g r e e i n
I n t h e p a s t , s h a f t g r o u n d i n g brushes were n o t i n s t a l - t h o s e s t a g e s where t h e steam i s s t i l l superheated, b u t
l e d on some g e n e r a t o r s o r , i f i n s t a l l e d , w e r e u s u a l l y t h e p o t e n t i a l s induced a r e o f o p p o s i t e p o l a r i t y .
neglected. T h i s p r a c t i c e p r e s e n t e d no p r o b l e m s as T h e r e f o r e a l l t u r b i n e types are affected, i r r e s p e c t i v e
l o n g as t h e b e a r i n g and s e a l c l e a r a n c e s w e r e a d e q u a t e of t h e s h a f t arrangement. The r a t e o f c h a r g e s e p a r a -
and t h e s h a f t v o l t a g e was s m a l l . As t h e c l e a r a n c e s t i o n and hence v o l t a g e b u i l d up i s d i r e c t l y p r o p o r t i o n -
were reduced i n modern machines, t h e c h a n c e s o f v o l t - a l t o t h e steam f l o w r a t e and hence l o a d .
a g e b r e a k d o w n a c r o s s t h e gap i n c r e a s e d , c r e a t i n g a
r i s k o f b e a r i n g damage.
T h e r e i s more t h a n one s o u r c e f o r t h e v o l t a g e
t h a t i s found on t h e t u r b i n e g e n e r a t o r s h a f t o f a l l SHAFT VOLTAGE DUE TO CHARGE SEPARATION
m a c h i n e s . The m o t i o n o f t h e s t e a m f l o w i n g p a s t t h e
t u r b i n e b l a d e s i m p a r t s a v o l t a g e on t h e t u r b i n e r o t o r
d u e t o e l e c t r o s t a t i c c h a r g e s e p a r a t i o n . The e x c i t a -
t i o n system can c o n t r i b u t e v o l t a g e due t o h a r m o n i c s i n
t h e f i e l d v o l t a g e waveform. M a g n e t o s t r i c t i o n , and
magnetic asymmetry a r e o t h e r s o u r c e s . A l l of t h e s e
w i l l be d i s c u s s e d i n d e t a i l .
Normally, t h e expected v o l t a g e on t h e t u r b i n e
g e n e r a t o r s h a f t w i t h g r o u n d i n g b r u s h e s would n o t b e
above a p p r o x i m a t e l y 6 v o l t s peak t o peak. However, i f
t h e s h a f t g r o u n d i n g system i s n o t o p e r a t i n g p r o p e r l y ,
t h e v o l t a g e c o u l d b u i l d t o o v e r 150 v o l t s p e a k t o
peak.
The a u t h o r s have seen s e v e r a l i n s t a n c e s a t d i f f e r -
e n t u n i t s a t o u r u t i l i t y where t h e presence and m a g n i -
t u d e o f t h e s h a f t v o l t a g e c o n t r i b u t e d t o component
f a i 1u r e .

8 7 SM 603-4 A paper recommended and approved

tby the IEEE Rotating Machinery Committee of the 0 10 20 U)

IEEE Power Engineering Society for presentation at

w1u1scoHIs
the IEEE/PES 1987 Summer Meeting, San Francisco,
California, July 12 - 17, 1987. Manuscript
submitted August 29, 1986; made available for
printing April 2 1 , 1987. Figure 1
0885-8969/88/0900-0607$01 .WO1988 IEEE
608

The p o t e n t i a l on t h e s h a f t f r o m t h e above source l i m i t e d o n l y b y t h e c i r c u i t impedance. Modern

i s d.c. A t y p i c a l v o l t a g e w a v e f o r m f o r a C r o s s Com- g e n e r a t o r s a r e e q u i p p e d w i t h i n s u l a t e d components,
pound 350 MW m a c h i n e i s shown i n F i g u r e 1, which was s u c h as b e a r i n g s o r s h a f t s e a l s , on a t l e a s t one end
taken w i t h t h e g r o u n d i n g b r u s h l i f t e d . I t i s charac- ( u s u a l l y t h e e x c i t e r end) t o p r e v e n t c i r c u l a t i n g
t e r i z e d b y a f a s t r a t e o f b u i l d up and an even f a s t e r currents. T h i s v o l t a g e i s v i r t u a l l y independent o f
r a t e o f d i s c h a r g e . The d i s c h a r g e i s c a u s e d b y b r e a k - l o a d and a t y p i c a l waveform i s shown i n F i g u r e 2.
down o f an o i l f i l m u s u a l l y ( b u t n o t a l w a y s ) i n t h e
p a r t w i t h t h e s m a l l e s t c l e a r a n c e when t h e s h a f t v o l t -
age has e l e v a t e d t o a s u f f i c i e n t l y h i g h l e v e l . W i t h SHAFT VOLTAGE DUE TO MAGNETIC ASYMMETRIES
t h e ground b r u s h l i f t e d , t h e s e v o l t a g e s w i l l a p p r o a c h
100 t o 150 v o l t s , d e p e n d i n g on t h e c o n d i t i o n o f t h e
l u b r i c a t i n g o i l / s e a l o i l and c l e a r a n c e s . W i t h o u t t h e
b r e a k d o w n o f t h e o i l , t h e s e v o l t a g e s would r e a c h v e r y
h i g h l e v e l s w e l l i n excess o f 10,000 v o l t s .
The s m a l l e s t c l e a r a n c e s a r e u s u a l l y seen i n t h e
p i l o t v a l v e and g o v e r n o r assembly o r across t h e gears
on gear d r i v e n e x c i t e r s . F o r t u n a t e l y , however, t h i s
s o u r c e o f s h a f t v o l t a g e has a h i g h s o u r c e impedance
and i s t h e r e f o r e r e l a t i v e l y weak and u n a b l e t o d r i v e
much c u r r e n t t o g r o u n d . T h i s does n o t mean t h a t i t
cannot cause damage because c u r r e n t d e n s i t i e s o f o n l y
a f e w m i l l i a m p s p e r square i n c h a r e capable o f causing
p i t t i n g t o t h e b a b b i t m a t e r i a l . Actual metal t r a n s f e r
t a k e s p l a c e and t h e p r o c e s s o f damage i s s i m i l a r t o
e l e c t r o d e p o s i t i o n m a c h i n i n g (EDM). T h e r e f o r e , one
p u r p o s e o f t h e b r u s h i s t o a c t as a f o r m o f s t a t i c
d r a i n t o t h e e l e c t r o s t a t i c c h a r g e s b u i l t up on t h e
shaft.

E x c i t a t i o n System as a Source

P o t e n t i a l s can a l s o b e induced b y c a p a c i t i v e cou-

p l i n g between t h e r o t o r f i e l d w i n d i n g and t h e s h a f t .
-ll.W\ , , , , , , , ,1
7
, ,. I . I , . I . I , . r T - r -

T h y r i s t o r c o n t r o l l e d e x c i t a t i o n systems c o n t a i n r e l a - 0 10 20 30 4
t i v e l y h i g h f r e q u e n c y components i n t h e i r o u t p u t v o l t - MnLIs3oKs
age w a v e f o r m and t h e s e can c o u p l e t o t h e s h a f t v i a t h e
c a p a c i t a n c e b e t w e e n t h e f i e l d w i n d i n g and t h e r o t o r
forging. Unless p r o p e r use i s made o f f i l t e r s o r wave Figure 2
t r a p s , t h e s e h a r m o n i c components c a n f o r m an a d d i -
t i o n a l s o u r c e o f i n d u c e d p o t e n t i a l on t h e s h a f t and Magnetized R o t a t i n g Components
p o s s i b l e damage.
When d i o d e s o r t h y r i s t o r s a r e b l o w n , o r f a u l t s The l a s t s o u r c e o f c u r r e n t s i s d u e t o t h e pos-
occur i n t h e g a t e t r i g g e r i n g c i r c u i t s , a s e r i e s o f so s i b i l i t y o f the turbine c y l i n d e r l s h e l l combination
c a l l e d " u n c h a r a c t e r i s t i c " (even) harmonics can appear a c t i n g as a p e r m a n e n t m a g n e t i c g e n e r a t o r . Both t h e
i n t h e f i e l d v o l t a g e waveform w h i c h a r e f i l t e r e d l e s s s t a t i o n a r y and r o t a t i n g t u r b i n e b l a d e s / b u c k e t s a r e
e f f e c t i v e l y t h a n t h e normal " c h a r a c t e r i s t i c " (odd) c a p a b l e o f m a g n e t i z a t i o n b y m a g n e t o s t r i c t i o n and can
harmonics. These harmonic components w h i c h a p p e a r as f o r m an a d d i t i o n a l source o f v o l t a g e C31. T h i s i s an
r i p p l e superimposed on t h e f i e l d v o l t a g e c o u p l e t o t h e a.c. s o u r c e , r i c h i n h a r m o n i c s a t t h e b l a d e p a s s i n g
s h a f t v i a t h e p o t e n t i a l d i v i d e r which i s f o r m e d b y t h e frequencies, b u t i t i s a l s o a r e l a t i v e l y weak s o u r c e .
s e r i e s c o n n e c t i o n o f t h e winding capacitance t o s h a f t I t i s t h e l e a s t i m p o r t a n t o f t h e common s o u r c e s i n
and t h e s h a f t impedance t o ground. t u r b i n e t y p e generators, a l t h o u g h i t i s very i m p o r t a n t
T h i s source i s a l s o weak and i n c a p a b l e o f d r i v i n g i n h i g h speed a x i a l f l o w c o m p r e s s o r s t y p i c a l l y used
l a r g e c u r r e n t s t o ground, b u t again, i t i s capable o f f o r soot blowing o r o t h e r a p p l i c a t i o n s i n t h e p e t r o -
c a u s i n g damage t o t h e b e a r i n g s u r f a c e s . Voltages o f chemical i n d u s t r i e s .
t h e o r d e r 10 t o 20 v o l t s b e t w e e n m a j o r p e a k s a r e
p o s s i b l e . The magnitude and f r e q u e n c y d i s t r i b u t i o n o f
t h i s v o l t a g e i s d e p e n d e n t on whether t h e y a r e caused
b y c h a r a c t e r i s t i c o r u n c h a r a c t e r i s t i c h a r m o n i c s and
a l s o upon t h e l o a d . I t i s a l s o dependent on t h e s h a f t
impedance t o ground. 5 BRUSH

Magnetic Asymmetries

The m o s t i m p o r t a n t source o f p o t e n t i a l l y damaging

levels of shaft voltage are induced b y t h e generator
i t s e l f C21. Any mechanism which r e s u l t s i n a n e t f l u x
l i n k i n g w i t h t h e r o t o r s h a f t i s capable o f causing
voltages of t h i s kind. One cause o f t h i s phenomenon
i s due t o asymmetrics i n t h e s t a t o r m a g n e t i c c i r c u i t
w h i c h c a u s e t h e f l u x l e a v i n g t h e r o t o r t o d i v i d e un-
6 RF2 cF2 COUPL I NG

e v e n l y when e n t e r i n g t h e s t a t o r . T h e n e t d i s s y m m e t r y
l i n k s t h e r o t o r s h a f t and i n d u c e s a s h a f t p o t e n t i a l .
T h i s v o l t a g e i s u s u a l l y b e t w e e n 30 and 60 v o l t s peak H2 SEAL BEARINGS
t o peak and i s r i c h i n h a r m o n i c s , i n a d d i t i o n t o t h e
fundamental o f 60Hz. F u r t h e r causes a r e e c c e n t r i c a l l y
m o u n t e d r o t o r s , and r o t o r sag. These s o u r c e s a r e
s t r o n g because t h e y have low s o u r c e i m p e d a n c e and a r e
c a p a b l e o f d r i v i n g l a r g e c u r r e n t s t o ground which a r e F i g u r e 3: Equivalent C i r c u i t
 609

E q u i v a l e n t C i r c u i t o f S h a f t P o t e n t i a l Sources w i t h t h e b r u s h l i f t e d and w i t h n o b r e a k o v e r o f a n y
p a r a l l e l o i l f i l m ) and t h e s h o r t c F c u i t c u r r e n t ( i . e .
An e q u i v a l e n t c i r c u i t showing t h e r e l a t i o n s h i p o f t h e c u r r e n t w i t h t h e brush i n contact w i t h t h e s h a f t )
t h e v a r i o u s v o l t a g e sources i s shown i n F i g u r e 3. As i s of t h e o r d e r 2 t o 5 amperes. An i m p e d a n c e o f 3000
c a n b e seen, i n o r d e r t o p r e v e n t c i r c u l a t i n g c u r r e n t s , t o 5000 ohms ( c o r r e s p o n d i n g t o a s e r i e s c a p a c i t a n c e o f
i n s u l a t i o n t o ground m u s t b e p r o v i d e d f o r a l l compo- about 0.45 m i c r o f a r a d s a t a r e p e t i t i o n r a t e o f 8
n e n t s a t t h e e x c i t e r end o f t h e machine, i n c l u d i n g t h e mSecs) i s t h e r e f o r e t y p i c a l f o r t h i s source.
e x c i t e r coupling, thermocouples, s h a f t r i d e r s and S i m i l a r l y , f o r t h e g e n e r a t o r as a s o u r c e , t h e
o t h e r s i m i l a r components. p a t h f o r c u r r e n t i s a l o n g t h e s h a f t , across t h e b e a r -
i n g o i l f i l m ( s ) and b e a r i n g i n s u l a t i o n , r e t u r n i n g
Measurement o f Shaft V o l t a g e t h r o u g h t h e t u r b i n e and g e n e r a t o r c a s i n g s and t h e gen-
e r a l p l a n t g r o u n d mass. The b e a r i n g i n s u l a t i o n i s
Measure t h e voltage c o n t r i b u t i o n s from charge t h e p r e d o m i n a n t component o f t h e c i r c u i t impedance.
s e p a r a t i o n and m a g n e t i z e d r o t a t i n g c o m p o n e n t s ( P M G ) , If t h i s c i r c u i t i s approximated as two c o n c e n t r i c c y l -
w i t h t h e m a c h i n e r u n n i n g u n e x c i t e d a t r a t e d speed. i n d e r s ( t h e i n n e r member b e i n g t h e s h a f t and t h e o u t e r
Some t u r b i n e t y p e s a r e i n c a p a b l e o f b e i n g r u n i n t h i s member t h e t u r b i n e and g e n e r a t o r c a s i n g ) , t h e i n d u c -
mode f o r l o n g p e r i o d s b e c a u s e of t h e l o s s o f c o o l i n g t a n c e o f t h e c i r c u i t can be c a l c u l a t e d .
i n t h e l o w p r e s s u r e s t a g e s due t o t h e l o w e r s t e a m F o r a 150 f o o t s h a f t l i n e , w i t h a 1 6 i n c h s h a f t
flows. Care must t h e r e f o r e b e t a k e n when making t e s t s d i a m e t e r and 18 i n c h average b l a d e l e n g t h ( o n a 500 MW
o f t h i s n a t u r e . The s h a f t v o l t a g e due t o c h a r g e s e p a - 4 f l o w t u r b i n e , t h e h.p. b l a d e s w o u l d b e a b o u t 5
r a t i o n can b e measured a t t h e g r o u n d i n g brush loca- i n c h e s l o n g a n d t h e LP L - 0 s t a g e b l a d e s a b o u t 3 3
t i o n , w i t h t h e b r u s h l i f t e d , and i s c h a r a c t e r i z e d a s i n c h e s ) , t h e impedance a t 60 Hz w o u l d b e a b o u t 1 . 5 t o
h i g h f r e q u e n c y " h a s h " as shown i n F i g u r e 1. S h a f t 2 . 5 ohms. I t i s l a r g e l y dependent on t h e i n t e r n a l
v o l t a g e due t o magnetized r o t a t i n g components i s r e l a - f l u x l i n k a g e s i n t h e s h a f t and s h e l l and on t h e perme-
t i v e l y c o n s t a n t , p r o p o r t i o n a l t o s h a f t speed and b l a d e a b i l i t y o f t h e s h a f t and c a s i n g m a t e r i a l s . O f course,
p a s s i n g frequency, and s h o u l d be m e a s u r e d a c r o s s e a c h t h e p a t h f o r t h e c u r r e n t may be much s h o r t e r t h a n 150
t u r b i n e component. f e e t , i n w h i c h case t h e impedance w i l l b e reduced. I n
M e a s u r e t h e amount o f e x c i t a t i o n r i p p l e p r e s e n t g e n e r a l terms, i t would n o t be e x p e c t e d t h a t t h e gen-
b y m o n i t o r i n g t h e a.c. component o f t h e m a i n f i e l d e r a t o r w o u l d c i r c u l a t e much m o r e t h a n a maximum o f
voltage. about 100 t o 200 amperes even under w o r s t c o n d i t i o n s .
To i s o l a t e t h e v o l t a g e c o n t r i b u t i o n f r o m magnetic
a s y m m e t r i e s , v o l t a g e m e a s u r e m e n t s s h o u l d b e made Components a t R i s k
across t h e generator, p r e f e r a b l e w i t h a d i f f e r e n t i a l
i n p u t o s c i l l o s c o p e t o a v o i d g r o u n d i n g problems. It i s The c o m p o n e n t s p r i m a r i l y a t r i s k a r e t h r u s t and
a l s o u s e f u l t o m e a s u r e t h e v o l t a g e across each i n s u - j o u r n a l b e a r i n g s , o i l and h y d r o g e n s e a l s , g o v e r n o r ,
l a t e d component and t h e c u r r e n t i n t h e g r o u n d i n g o i l pumps a n d o t h e r g e a r d r i v e n a u x i l i a r i e s . The
b r u s h . C a r e must b e t a k e n t o u s e a n o n - i n d u c t i v e shunt s t a n d a r d method o f p r o t e c t i o n i s i n s u l a t i o n o f t h e
f o r b r u s h c u r r e n t measurement, and a l s o t o a v o i d i n - g e n e r a t o r - e x c i t e r c o u p l i n g and i n s u l a t i o n o f a1 1 com-
a d v e r t e n t l y b r i d g i n g t h e e x c i t e r end b e a r i n g o r s e a l p o n e n t s a t t h e e x c i t e r end o f t h e g e n e r a t o r . The
insulation. Interpretation of the voltage across r e a s o n f o r t h i s i s c l e a r l y shown b y F i g u r e 3. The
t h e s e c o m p o n e n t s m u s t b e made r e c o g n i z i n g t h a t t h e grounding b r u s h p r o v i d e s a ground o r z e r o r e f e r e n c e
c a p a c i t i v e r e a c t a n c e o f t h e i n s u l a t i o n and o i l f i l m s and i s n o r m a l l y p o s i t i o n e d a t t h e t u r b i n e end o f t h e
may b e t h e d o m i n a n t i m p e d a n c e component i f t h e f r e - generator. What t h i s s e l e c t i o n o f p o s i t i o n e s s e n -
quency o f t h e v o l t a g e i s h i g h . Good d . c . r e s i s t a n c e t i a l l y does i s t o a p p l y t h e g e n e r a t o r s h a f t voltage
i s n o t t h e o n l y y a r d s t i c k t h a t needs t o be used. across t h e b e a r i n g , s e a l and c o u p l i n g i n s u l a t i o n a t
t h e e x c i t e r end and s i m u l t a n e o u s l y a l l o w s t h e b r u s h t o
MECHANICAL COMPONENT FAILURE be c l o s e t o t h e source o f e l e c t r o s t a t i c b u i l d up, i . e .
i n t h e LP stages o f t h e t u r b i n e .
F a i l u r e Modes W h i l e s h a f t c u r r e n t s c e r t a i n l y o b e y t h e Laws o f
P h y s i c s , t h e y d o n o t a l w a y s seem t o obey t h e laws o f
Any p r e c i s i o n m a c h i n e d component where r e l a t i v e human l o g i c . T h i s c h o i c e o f g r o u n d i n g b r u s h p o s i t i o n
m o t i o n o c c u r s b e t w e e n a component a t t a c h e d t o t h e h a s n o t b e e n f o u n d t o b e u n i v e r s a l l y e f f e c t i v e and
s h a f t and one t o t h e t u r b i n e o r g e n e r a t o r base i s a c u r r e n t s w i l l s t i l l o c c a s i o n a l l y damage c o m p o n e n t s i n
p o t e n t i a l source o f f a i l u r e f r o m s h a f t v o l t a g e . t h e f r o n t s t a n d a r d a r e a . T h i s i s because t h e s h a f t i s
As a g e n e r a l r u l e , f a i l u r e d o e s n o t come a b o u t n o t an e q u i p o t e n t i a l s u r f a c e and t h e v o l t a g e i s d i s t r i -
f r o m o v e r h e a t i n g caused b y h i g h c u r r e n t s , even i f t h e buted non-uniformly along t h e length o f t h e shaft.
source o f t h e c u r r e n t i s t h e g e n e r a t o r . This i s Therefore, i t i s o c c a s i o n a l l y found n e c e s s a r y t o add a
because t h e components a f f e c t e d are g e n e r a l l y large, s e c o n d b r u s h i n t h e head end b e a r i n g a r e a t o p r o t e c t
and can, a t l e a s t so f a r a s b e i n g an e l e c t r i c a l c o n - t h e governor.
d u c t o r i s concerned, c a r r y r e l a t i v e l y large currents
( s a y 100 a m p e r e s ) . Secondly, t h e l o o p impedance The E f f e c t s o f L u b r i c a t i n g O i l Contamination
t h r o u g h w h i c h t h e s e c u r r e n t s h a v e t o f l o w i s n o t as
s m a l l as m i g h t b e imagined, e s p e c i a l l y s i n c e a t l e a s t Contamination o f any kind i n the l u b r i c a t i n g o i l
o n e p a r t o f t h e c i r c u i t i s composed o f an o i l f i l m . i s u n d e r s t a n d a b l y b a d and i t i s h i g h l y a b n o r m a l t o
Rather, f a i l u r e i s normally o f a mechanical n a t u r e f i n d p a r t i c u l a t e s i n t h e o i l u n l e s s a b e a r i n g i s under-
f o l l o w i n g p i t t i n g o f t h e b e a r i n g s u r f a c e s and damage going f l a k i n g o f t h e b a b b i t m a t e r i a l . I n any event,
t o o t h e r c l o s e t o l e r a n c e machined s u r f a c e s . E s s e n t i a l - t h i s w o u l d b e c a u g h t i n s t r a i n e r s downstream. Some
l y , p i t t i n g c o n t i n u e s u n t i l t h e bearing loses i t s low degree o f water c o n t a m i n a t i o n i s , however, q u i t e
coefficient o f f r i c t i o n , the losses increase, t h e common, a l t h o u g h s t i l l u n d e s i r a b l e . Water contami-
b e a r i n g s u r f a c e breaks up and t h e s u r f a c e i s wiped. n a t i o n p r o m o t e s f o a m i n g , e m u l s i f i c a t i o n and s l u d g e
f o r m a t i o n and i s a c o n t r i b u t o r y f a c t o r i n a c c e l e r a t e d
Loop Impedances b e a r i n g wear and s h a f t c u r r e n t s .
Above a v a l u e o f a b o u t 80 ppm o f w a t e r , t h e d i -
The impedance t o t h e e l e c t r o s t a t i c discharge e l e c t r i c s t r e n g t h o f t h e o i l i s c o n s i d e r a b l y reduced
c u r r e n t can b e a p p r o x i m a t e d b y c o n s t r u c t i n g a s i m p l e which can p r o m o t e p r e m a t u r e e l e c t r i c a l b r e a k d o w n o f
T h e v e n i n e q u i v a l e n t c i r c u i t . The open c i r c u i t v o l t a g e the o i l f i l m .
i s o f t h e o r d e r 10000 t o 20000 v o l t s ( i . e . t h e v o l t a g e
610

C o n t a m i n a t i o n o f t h e l u b r i c a t i n g o r seal o i l The s e l e c t i o n o f t h e coup1 i n g c a p a c i t o r depends

system b y m o i s t u r e can be caused b y l e a k y steam s e a l s , on t h e m a c h i n e c a p a c i t a n c e w h i c h i s a f u n c t i o n o f
c o o l e r l e a k s and t h e l i k e . Steam l e a k i n g f r o m steam steam p r e s s u r e and t e m p e r a t u r e , t u r b i n e e f f i c i e n c y ,
seals i s pulled i n t o the lube o i l system b y t h e bear- s t e a m c o n d i t i o n s , and t h e r a t e o f v o l t a g e b u i l d - u p
i n g o i l v a p o r e x t r a c t o r v i a bearings adjacent t o t h e w h i c h i s a f u n c t i o n o f l o a d . A h i g h impedance ca-
l e a k i n g seals. p a c i t o r discharge r e s i s t o r would be r e q u i r e d f o r
C o n t a m i n a t i o n o f t h e l u b r i c a t i n g o i l b y water i s
u n d e s i r a b l e because i t can g e n e r a t e severe w e i g h t l o s s
safety .
i n l e a d - b a s e b a b b i t due t o o x i d a t i o n . As a c o n s e - Compos it i on
quence t h e l i f e o f t h e b e a r i n g i s s i g n i f i c a n t l y r e -
duced, p e r h a p s b y a f a c t o r o f 3 t o 10 o r even more i n G e n e r a l l y , t h e r e a r e two t y p e s o f brushes i n
severe cases. G e n e r a l l y speaking, a goal o f a b o u t 100 common use, c o p p e r b r a i d s o r c a r b o n c o m p o s i t e s .
ppm m o i s t u r e c o n t e n t i s a c c e p t a b l e , a l t h o u g h h i g h e r A l t h o u g h c o p p e r b r a i d s a r e s i m p l e r , and may appear t o
amounts can b e t o l e r a t e d . ( I t should be noted t h a t r e q u i r e l e s s m a i n t e n a n c e , t h e y h a v e some d r a w b a c k s .
f r o m a s t r i c t l y mechanical viewpoint, a moisture P r i m a r i l y , t h e s h a f t m u s t b e v e r y smooth so t h a t t h e
c o n t e n t o f 100 ppm o r more i s considered a c c e p t a b l e . ) e n t i r e s u r f a c e o f t h e b r a i d i s making c o n t a c t w i t h t h e
s h a f t and t h e r e a r e no h o t s p o t s , o r a r c i n g . A r c i n g
INSTALLATION AND MAINTENANCE may i n d u c e v o l t a g e s p i k e s on t h e s h a f t w h i c h c o u l d
c r e a t e p r o b l e m s i n o t h e r areas, o r cause t h e b r a i d t o
Location overheat, b u r n and p e r h a p s damage t h e s h a f t . I t can
b e d i f f i c u l t t o change a copper b r a i d w h i l e t h e u n i t
Grounding brushes are usually located a t the i s on l i n e , and e v e n i f t h e u n i t i s s h u t down, t h e
t u r b i n e end o f t h e g e n e r a t o r . They s h o d l d n o t b e p r o c e s s i s n o t as s i m p l e as c a r b o n brushes. Another
l o c a t e d a t t h e e x c i t e r end which i s i n s u l a t e d t o p r e - weakness w i t h t h e b r a i d i s t h e d i f f i c u l t y o f m a i n -
v e n t c i r c u l a t i n g c u r r e n t s . The m o s t i m p o r t a n t f a c t o r t a i n i n g constant pressure which could also lead t o
i n choosing t h e s p e c i f i c l o c a t i o n i s accessibility. a r c i n g . Copper b r a i d s a r e u s e f u l f o r s t a t i c d r a i n .
The brushes must be i n an area t h a t can b e r e a d i l y and Carbon composites a r e n o t as s u s c e p t i b l e t o h o t
s a f e l y a c c e s s e d f o r m a i n t e n a n c e , i n s p e c t i o n , and spots. However, due t o t h e r e l a t i v e l y l o w c u r r e n t
testing. I t may become n e c e s s a r y t o m o n i t o r b r u s h d e n s i t y , t h e carbon b r u s h i s s u b j e c t t o g l a z i n g . If
c u r r e n t o r s h a f t v o l t a g e w h i l e t h e u n i t i s on l i n e . t h e b r u s h e s do become g l a z e d , t h e v o l t a g e w i l l b u i l d
T h e r e f o r e t h e y should n o t be p l a c e d i n an e n v i r o n m e n t up t o t h e breakdown l e v e l and t h e n a r c o v e r t h e g l a z e
t h a t i s e x c e s s i v e l y h o t p r e v e n t i n g o r l i m i t i n g safe creating voltage spikes. S i l v e r , o r c o p p e r impreg-
access. A t l e a s t two b r u s h e s s h o u l d b e i n s t a l l e d a t nated g r a p h i t e brushes should be used t o m i n i m i z e t h i s
t h e same s h a f t l o c a t i o n . To i n s u r e t h a t t h e brushes problem and t o reduce t h e v o l t a g e d r o p across t h e f i l m .
a r e always making good e l e c t r i c a l c o n t a c t , t w o c o n d i - The carbon b r u s h should b e i n s t a l l e d i n a c o n v e n t i o n a l
t i o n s s h o u l d b e o b s e r v e d : F i r s t , t h e brushes should c o n s t a n t p r e s s u r e b r u s h h o l d e r which w i l l p r o v i d e good
be i n s t a l l e d a t a n i n e t y degree a n g l e so t h a t a t l e a s t c o n t a c t , and e a s e o f r e p l a c e m e n t b y t h e o p e r a t i n g
one b r u s h i s a l w a y s making c o n t a c t w i t h t h e s h a f t r e - personnel.
gardless o f i t ' s r e l a t i v e motion. Second, t h e s h a f t
s h o u l d b e t r u e d , and p o l i s h e d w i t h a stone t o p r o v i d e Maintenance
a smooth s u r f a c e f o r t h e b r u s h t o r i d e on. This i s
v e r y i m p o r t a n t t o p r e v e n t h o t s p o t s on t h e b r u s h o r S i n c e t h e brushes a r e s u b j e c t t o wear, t h e i r con-
s h a f t due t o r e l a t i v e l y l a r g e c u r r e n t d e n s i t y i n a d i t i o n should be checked p e r i o d i c a l l y a t l e a s t once
small area. p e r week i s recommended. The i n t e g r i t y o f t h e
To i n s u r e adequate brush c o n t a c t , a dedicated grounding system can b e v e r i f i e d b y s i m p l y m e a s u r i n g
s l i p r i n g c o u l d b e l o c a t e d on t h e s h a f t . This s l i p t h e s h a f t v o l t a g e t o ground u s i n g a s h a f t r i d i n g hand
r i n g w o u l d b e e a s i l y m a i n t a i n e d , and would e l i m i n a t e h e l d probe. Commercial ground b r u s h m o n i t o r i n g
t h e n e c e s s i t y o f machining t h e s h a f t i t s e l f . d e v i c e s a r e a l s o a v a i l a b l e . T y p i c a l l y , v o l t a g e s range
The b r u s h e s s h o u l d b e c o n n e c t e d t o t h e u n i t up t o 6 v o l t s peak t o peak, and a r e m i c r o s e c o n d s i n
g r o u n d mass u t i l i z i n g t h e ground conductors which a r e duration. One m a j o r m a n u f a c t u r e r has p u b l i s h e d a
connected t o t h e t u r b i n e end g e n e r a t o r frame. Provide t h r e s h o l d o f 6 v o l t s peak t o peak. V o l t a g e s above
a few f e e t o f i n s u l a t e d c a b l e f r o m t h e b r u s h h o l d e r t o t h i s l e v e l means t h e g r o u n d i n g s y s t e m s h o u l d be
t h e g r o u n d c o n d u c t o r t o a l l o w c o n n e c t i o n o f a non- checked and overhauled i f r e q u i r e d . The b e s t i n s t r u -
i n d u c t i v e c u r r e n t s e n s i n g probe f o r m o n i t o r i n g o f t h e ment f o r m e a s u r i n g t h e s h a f t v o l t a g e i s a dual t r a c e
ground c u r r e n t . d i f f e r e n t i a l i n p u t o s c i l l o s c o p e w h i c h a l l o w s com-
As an a d d i t i o n t o c o n v e n t i o n a l grounding brushes, parison o f s h a f t voltage a t different locations.
o u r company has begun an i n v e s t i g a t i o n i n t o t h e i n s t a l - W h a t e v e r i n s t r u m e n t i s used, i t s h o u l d h a v e a h i g h
l a t i o n a c a p a c i t i v e l y c o u p l e d ground system. Such a i n p u t impedance. A p p r o p r i a t e compensation i s neces-
system would ground t h e a.c. component, b u t n o t a l l o w s a r y when u s i n g m e t e r s w i t h s l o w r e s p o n s e t o h i g h
d.c. c i r c u l a t i n g c u r r e n t . T h i s b r u s h would be l o c a t e d frequency signals. The t e s t l e a d s must be a d e q u a t e l y
a t t h e #7 b e a r i n g ( s e e F i g u r e 4 ) w h i c h has a h i s t o r y s h i e l d e d t o e l i m i n a t e f a l s e s i g n a l s such as h i g h i n t e n -
of pitting. s i t y l i g h t i n g , arc welding o r o t h e r noise.
The b r u s h i t s e l f should be c h e c k e d f o r wear, r e -
p l a c e d if n e c e s s a r y , and t h e c l i p c o n t a c t s should be
cleaned. T h i s i s a good t i m e t o check b r u s h p r e s s u r e ,
SECONDPRY GRWND BRUSH PRIMARY GPWND BRUSH w h i c h s h o u l d b e m a i n t a i n e d a t about 3.75 p s i . Exces-
&IRING s i v e b r u s h p r e s s u r e may l e a d t o o t h e r problems s u c h as
6 7
shaft vibration. The s h a f t c o n d i t i o n s h o u l d be
checked f o r g l a z i n g , p i t t i n g o r s c o r i n g . If i t i s
s l i g h t l y g l a z e d i t can b e c l e a n e d up b y p r e s s i n g a
canvas s t i c k a g a i n s t t h e s h a f t w h i l e r u n n i n g a t speed.
More s e r i o u s d e t e r i o r a t i o n may r e q u i r e c o r r e c t i o n by
stoning the shaft.
I f t h e s h a f t grounding system f a i l s , i t could
l e a d t o problems w i t h o t h e r components s u c h as g e a r s ,
o i l pumps, b e a r i n g s , o i l s e a l s , o r h y d r o g e n s e a l s .
F i g u r e 4: L o c a t i o n o f Grounding Brushes These components s h o u l d be checked d u r i n g r o u t i n e
 61 1

m a i n t e n a n c e f o r p i t t i n g (commonly c a l l e d f r o s t i n g ) . From t h i s w o r k a s c e n a r i o o f t h e m o s t p r o b a b l e
P i t t i n g i s caused b y a r c i n g across t h e b e a r i n g o r s e a l c a u s e o f t h e g o v e r n o r s h a f t f a i l u r e was d e v e l o p e d .
o i l f i l m , and i f l e f t u n c o r r e c t e d , i t can l e a d t o t h e When t h e r e p a i r e d governor assembly was i n s t a l l e d , t h e
component f a i l u r e . g o v e r n o r s h a f t b e a r i n g c l e a r a n c e was s m a l l e r t h a n
Some m a c h i n e s a r e e q u i p p e d w i t h b r u s h e s on t h e b e f o r e . T h i s , t o g e t h e r w i t h t h e f a c t t h a t t h e ground-
f r o n t s t a n d a r d n e a r t h e PMG o r g o v e r n o r . I f these i n g brushes w e r e i n e f f e c t i v e , a l l o w e d a r c i n g a c r o s s
b r u s h e s a r e removed, i t i s e s s e n t i a l t h a t t h e s h a f t t h e bearings which p a r t i a l l y destroyed t h e bearing
c o u p l i n g be i n s u l a t e d t o p r e v e n t c i r c u l a t i n g c u r r e n t s s u r f a c e . A s l i p - s t i c k t y p e o f f r i c t i o n was t h e r e s u l t
t h r o u g h t h e r e l a t i v e l y s m a l l c l e a r a n c e s a t t h i s end. w h i c h s e t up t h e t o r s i o n a l o s c i l l a t i o n and o v e r h e a t i n g
of t h e s h a f t .
RESULTS AND EXPERIENCE
S i t e Experience #2
S i t e Experience # 1
A n o t h e r u n u s u a l e x p e r i e n c e w h i c h we had w i t h
R e c e n t l y , we experienced a s e r i e s o f f a i l u r e s a t a 350 g r o u n d i n g brushes was on a 500 MW tandem compound u n i t
MW c r o s s compound h i g h p r e s s u r e t u r b i n e g e n e r a t o r . w h i c h h a d t w o 1 . 5 x 0.75 i n c h g r o u n d i n g brushes l o -
The g o v e r n o r p i l o t v a l v e f a i l e d f i r s t , a p p a r e n t l y f r o m c a t e d a t t h e t u r b i n e end o f t h e g e n e r a t o r .
f o r e i g n m a t e r i a l , and t h e c o m p l e t e g o v e r n o r a s s e m b l y T h i s u n i t was i d e n t i c a l t o s e v e r a l m a c h i n e s t h a t
was s e n t o u t f o r r e p a i r . When t h e governor assembly h a d f a i l e d d u e t o r u p t u r e d b l o w e r s p a c e r s and natu-
was r e t u r n e d f r o m t h e shop, i t h a d b e e n c o m p l e t e l y r a l l y we w e r e u n u s u a l l y s e n s i t i v e t o t h e v i b r a t o r y
r e f u r b i s h e d i n c l u d i n g new b e a r i n g s . The new b e a r i n g s h e a l t h o f t h e machine. T h i s m a c h i n e was a l s o o n e
had reduced c l e a r a n c e s f r o m t h e o r i g i n a l s p e c i f i c a t i o n . which h i s t o r i c a l l y had p o o r c o r r e l a t i o n o f hand h e l d
The u n i t was p l a c e d i n s e r v i c e and o p e r a t e d f o r about v i b r o m e t e r measurements w i t h t h o s e g i v e n by c o n t r o l
40 hours when t h e governor s p l i n e s h a f t f a i l e d . Again room i n s t r u m e n t a t i o n . T h i s was c o r r e c t e d b y r e r o u t i n g
t h e e n t i r e g o v e r n o r a s s e m b l y was r e p a i r e d w i t h new c a b l e s away f r o m t h e i s o l a t e d p h a s e b u s and p l a c i n g
b e a r i n g s . When t h e u n i t was p l a c e d back i n t o s e r v i c e , t h e complete c a b l e r u n i n s t e e l c o n d u i t .
i t r a n f o r a b o u t f o u r h o u r s when t h e new g o v e r n o r Our f i r s t e v i d e n c e o f a p o t e n t i a l p r o b l e m was a
s h a f t f a i 1ed . g r a d u a l i n c r e a s e i n t h e v i b r a t i o n l e v e l on t h e t u r b i n e
An a n a l y s i s o f t h e f a i l u r e s r e v e a l e d t h a t b o t h end g e n e r a t o r b e a r i n g ( # 7 ) . The a c t u a l r e a d i n g s f r o m
governor s h a f t s were r a p i d l y heated t o t h e m e l t i n g t h e i n c i d e n t a r e shown i n F i g u r e s 5 and 6.
p o i n t o f 17800K, t h e n cooled. Two p o s s i b l e sources o f
h e a t were p o s t u l a t e d . E i t h e r t h e s o u r c e o f h e a t was
e l e c t r i c a l ( h i g h c u r r e n t ) , o r mechanical (torsional
oscillations).
I f t h e s o u r c e o f h e a t i n g was e l e c t r i c a l , t h e
immediate q u e s t i o n was: "How much c u r r e n t w o u l d b e SHAFT VIBRATION
r e q u i r e d t o heat t h e s h a f t t o t h e m e l t i n g p o i n t ? "
T h i s c u r r e n t was c a l c u l a t e d b y a s s u m i n g t h a t a l l o f
t h e power i n p u t w o u l d be r a d i a t e d , w i t h no c o n v e c t i o n
n o r conduction, which y i e l d s a c o n s e r v a t i v e r e s u l t . '*i
The c a l c u l a t i o n i n d i c a t e d t h a t t h e c u r r e n t r e -
q u i r e d t o r a i s e t h e s h a f t temperature t o m e l t i n g would
b e a b o u t 5000 amperes f o r a b o u t 50 seconds, f a r i n
e x c e s s o f a n y c o n c e i v a b l e source, t h e r e b y e l i m i n a t i n g
s h a f t c u r r e n t as a p o s s i b l e c o n t r i b u t i n g c a u s e o f t h e
failure.
E x a m i n a t i o n o f v a r i o u s components i n t h e g e n -
; i
A '
e r a t o r revealed severe overheating o f t h e governor
s h a f t b e a r i n g s , and p i t t i n g on o t h e r b e a r i n g s and t h e
e x c i t e r end hydrogen s e a l . The n e x t step, a f t e r t h e A
u n i t w a s r e t u r n e d t o s e r v i c e , was t o m e a s u r e t h e
t u r b i n e s h a f t v o l t a g e w i t h r e s p e c t t o ground. Measure-
m e n t s o f u p t o 100 v o l t s peak t o peak w e r e o b t a i n e d
indicating t h a t the grounding brushes were n o t oper-
ating properly. I t would be f a i r t o p o i n t out t h a t
ii I

t h e o r i g i n a l brushes were i n s t a l l e d i n a l o c a t i o n t h a t i
v i r t u a l l y p r o h i b i t e d i n s p e c t i o n o r maintenance due t o ~

poor a c c e s s i b i l i t y , and e x c e s s i v e t e m p e r a t u r e s i n t h e
v i c i n i t y . A t one p o i n t a new copper b r a i d was i n s t a l -
l e d t o t r y t o reduce t h e s h a f t v o l t a g e . U n f o r t u n a t e l y ,
i * r~ -.,.--.. .T ~ . . ~ ~
-r r - r- - - T ----T
t h e s h a f t was n o t smooth, and t h e b r a i d began t o a r c 0 1 2 3 4 5 6 7 E 9 10 11 12 13 14
and b u r n due t o h i g h c u r r e n t d e n s i t y . The b r a i d was
removed i n f a v o r o f carbon composite brushes. HYRS
A c l o s e examination o f t h e g o v e r n o r s h a f t i t s e l f
i n d i c a t e d t h a t t h e s h a f t was s u b j e c t e d t o s e v e r e Figure 5
torsional oscillations. One of t h e f a i l e d s h a f t s h a d
s h e a r e d c o m p l e t e l y , t h e shear b e i n g a t an a n g l e o f 45 The a m p l i t u d e c h a n g e was a l s o a s s o c i a t e d w i t h an
degrees t o t h e s h a f t a x i s . S i n c e t h i s i s t h e a x i s o f a p p r o x i m a t e l y 35 degree change i n p h a s e a n g l e . After
t h e p r i n c i p a l s t r a i n s i n t o r s i o n , t h i s was no s u r p r i s e . c h e c k i n g a l l t h e obvious sources such as l u b e and s e a l
However, t h i s same s h a f t a l s o showed a s e c o n d a r e a o f o i l temperatures, r e c e n t a d d i t i o n s o f h y d r o g e n , l o o s e
s h e a r , a g a i n a t 45 d e g r e e s , b u t a t 90 degrees t o t h e v i b r a t i o n p i c k u p s , changes i n r e a c t i v e l o a d i n g e t c . ,
f i r s t . T h i s showed t h a t a t t h e t i m e o f f a i l u r e , t h e t h e m a c h i n e was o r d e r e d s h u t down. T h i s was d o n e
s h a f t was s u b j e c t e d t o a t o r s i o n a l o s c i l l a t i o n , w i t h a b e c a u s e t h e l e v e l o f v i b r a t i o n had reached o u r p r e v i -
node p o s i t i o n e d p a r t way a l o n g t h e s h a f t . A model o f o u s l y agreed maximum l e v e l and t h e c h a n g e s w e r e r a p i d
t h e s h a f t was c o n s t r u c t e d and s u b j e c t e d t o t o r s i o n a l and u n e x p l a i n a b l e .
I

oscillations. The model f a i l e d i n a s i m i l a r manner a s

the actual shaft.
612

l i k e l y t o be problematical.
SHAFT VIBRATION G r o u n d i n g schemes t o d a t e a r e more o f an a r t than
a science. I t appears t h a t a more a n a l y t i c a l a p p r o a c h
needs t o b e t a k e n i n t h e d e s i g n o f t u r b i n e g e n e r a t o r
s h a f t grounding.
41
REFERENCES

C11 G r u b e r , J.M. a n d Hansen, E.F." E l e c t r o s t a t i c

S h a f t V o l t a g e s on Steam T u r b i n e R o t o r s " , T r a n s
A S M E , V o l 8 1 , S e r i e s A, #1, J a n u a r y 1959, pp
m 0 .

C21 A l g e r , P.L. and Samson, W . " S h a f t C u r r e n t s i n

#8 E l e c t r i c Machines", A I E E Trans, V o l 4 3 , 1 9 2 4 , pp
235-245.

C31 S o h r e , J.S. and N i p p e s , P . I . " E l e c t r o m a g n e t i c

S h a f t C u r r e n t s i n Turbomachinery: An U p d a t e ,
P a r t s I and I I " , Amm. P l a n t Saf. Vol 23, 1981, pp
185-202.

C41 W a l k e r , J.H. " L a r g e S y n c h r o n o u s M a c h i n e s " ,

Clarendon Press, Oxford.
Figure 6 C51 B u c h a n a n . W. " C u r r e n t i n B e a r i n a s o f E l e c t r i c
G e n e r a t o r s " , E l e c t r i c i a n ( L a n d o n r , V o l 7 5 , May
The g e n e r a t o r was opened up and t h e b l o w e r spacer 28, 1915, pp 266-267.
and a s s o c i a t e d s e a l i n s p e c t e d . No p r o b l e m s w e r e de-
t e c t e d and t h e machine was r e t u r n e d t o s e r v i c e o n l y t o C61 M a z l a c k , S.W. "Magnetically Induced Shaft
have a second and s u b s e q u e n t l y t h i r d s i m i l a r i n c i d e n t . C u r r e n t s : Causes and C u r e s " , H y d r o c a r b o n
N a t u r a l l y , we w e r e i n t e r e s t e d i n f i n d i n g t h e l i k e l y Processing, August 1984, pp 61-65.
cause.
S e v e r a l p o s s i b l e c a u s e s w e r e p o s t u l a t e d such as C71 C a g g i a n o , J . L . " S h a f t V o l t a g e Measurement",
instrumentation e r r o r s , ground loops, s h o r t e d r o t o r Turbomachi n e r y I n t e r n a t io n a l , Ju 1y -Augu s t 1 9 8 3 ,
t u r n s and t h e grounding brushes. However, t h e c o n t r o l pp 29-31.
room v i b r a t i o n i n d i c a t i o n s were c o n f i r m e d b y h a n d h e l d
v i b r o m e t e r r e a d i n g s s o i n s t r u m e n t a t i o n e r r o r s and C8l I E E E G u i d e f o r O p e r a t i o n and Maintenance o f
g r o u n d l o o p s w e r e v i r t u a l l y d i s c o u n t e d as p o s s i b l e T u r b i n e Generators, I E E E Standard 68.
causes. I t was d u r i n g an i n v e s t i g a t i o n i n t o what was
t h o u g h t t o be t h e most u n l i k e l y c a u s e , t h e g r o u n d i n g C91 S t a n d a r d Handbook o f L u b r i c a t i o n E n g i n e e r i n g ,
b r u s h e s , t h a t we n o t i c e d t h a t l i f t i n g t h e grounding McGraw-Hi 11, 1968.
b r u s h c o u l d reduce t h e v i b r a t i o n l e v e l b y o v e r 0 . 0 0 2
i n c h e s peak t o p e a k . T h i s was an almost u n b e l i e v a b l e
r e s u It.
I t was a l s o n o t i c e d t h a t t h e phase a n g l e change Discussion
was a p p r o x i m a t e l y t w i c e t h e a n g u l a r spacing o f t h e t w o
g r o u n d i n g b r u s h e s a t #7 b e a r i n g . We p o s t u l a t e d t h a t K. Reichert and C. Ammann (Swiss Federal Institute of Technology,
t h e b r u s h generated a s m a l l h e a t a f f e c t e d zone w h i c h Zurich, Switzerland): This paper is a practical and therefore valuable
c o o l e d u n e v e n l y and which l e d t o a small s h a f t bow and contribution to the problem of shaft voltages in large turbosets. Especially
r e s u l t a n t v i b r a t i o n . T h i s proved t o be so even t h o u g h the two reported case histories show that the grounding brushes may cause
t h e c a l c u l a t e d f r i c t i o n h e a t i n g o f t h e s h a f t was l e s s unexpected effects. We are pleased to see that you obtained the same four
t h a n 2 kW [4]. A p p l i c a t i o n o f h i g h temperature con- types of sources for shaft voltages as we did in our paper.
d u c t i n g g r e a s e t o t h e b r u s h t r a c k was used i n i t i a l l y With respect to the shaft voltages due to static excitation systems, we
t o e l i m i n a t e t h e v i b r a t i o n f o r a week o r so. E v e n t u a l - would like to add the following remarks:
l y t h e b r u s h e s w e r e r e p l a c e d w i t h copper b r a i d , which
1) The equivalent circuit shown in Fig. 3 has to be complemented by
a t t h i s s i t e l o c a t i o n has b e e n s u c c e s s f u l . However,
inserting the capacitance of the excitation transformer to ground.
b r a i d s a r e n o t u s u a l l y our f i r s t choice.
I n t h i s case, u n u s u a l b e h a v i o r o f t h e g r o u n d i n g
2) The source of this type of shaft voltage is not the ac component of the
field voltage, but the common mode voltage of the rectifier. This voltage
b r u s h r e s u l t e d i n a l m o s t t e n days o f a d d i t i o n a l down
can be measured between the neutral point of the excitation transformer
time. and an artificial midpoint of the field winding.
CONCLUSIONS AND RECOMMENDATIONS Details may be found in [ 11. The model for the shaft voltage due to charge
separation consists more likely of a dc current source with a very high
T h e c o n c l u s i o n s r e a c h e d f r o m o u r own i n v e s t i - internal resistance. This source is charging the capacitance of the shaft
g a t i o n s are t h a t good e n g i n e e r i n g p r a c t i c e d i c t a t e s versus ground, which has a limited breakthrough capability on the order of
t h a t grounding brushes are a valuable addition t o a l l 100 V which can be seen in Fig. 1.
t u r b i n e generators, i r r e s p e c t i v e o f v i n t a g e . However,
p r o p e r p o s i t i o n i n g i s r e q u i r e d and t h e d e v i c e s must b e Reference
made a c c e s s i b l e f o r i n s p e c t i o n and maintenance.
[l] C. Ammann et al., "Shaft Voltages in Generators with Static
I n s t a l l a t i o n u n d e r a t u r b i n e s k i r t o r hood i s n o t Excitation Systems-Problems and Solution," IEEE-Paper 87SM
recommended. A l l grounding brushes should be 403-9.
i n s p e c t e d on a weekly b a s i s and r e p l a c e d f r e q u e n t l y .
I t s h o u l d be n o t e d t h a t any d e v i c e w h i c h i s i n Manuscript received August 6, 1987
r u b b i n g c o n t a c t w i t h t h e s h a f t has t h e c a p a b i l i t y o f
generating s u r p r i s i n g v i b r a t o r y behavior. Provided Paper released without Closure.
t h a t t h i s i s known b y o p e r a t i n g p e r s o n n e l i t i s n o t