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Damper Winding Fault Analysis in Synchronous Machines

Conference Paper · September 2018

DOI: 10.1109/ICELMACH.2018.8506800

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 Damper Winding Fault Analysis in Synchronous
Machines
Subrat Sahoo, Fredrik Holmgren, Pedro Rodriguez, Jose Perez and Urban Lundin
φρΦAbstract -- A Damper winding performs an important
function of protecting the Synchronous Motors (SMs) during
transient operations. They also happen to be one source of
concern for failure of SMs, which are otherwise quite reliable.
The situation aggravates when the motors are fed by variable
frequency drives, which brings additional stress on the damper
bars. This paper presents theoretical simulations of a salient
pole SM with twelve poles, containing three damper bars in each
pole, during healthy as well faulty damper bar conditions. The
current distribution is calculated in each damper bar.
Experiments were conducted on the same SM and the current in
the damper bars as well inter-connecting poles were measured
and captured on a rotating wireless communication platform,
both during healthy and faulty conditions of the damper bars
with varying severity. The fault indicators are presented to
detect damper bar failure conditions, thereby helping preventive
maintenance of SMs.
Index Terms- damper winding, synchronous motor, VFD,
transients, failure diagnostics, condition monitoring.
I. INTRODUCTION
T HE damper windings consist of axially oriented
conductor bars, usually made of copper, which are
located in the rotor poles, close to the airgap. The bars are
interconnected by so-called end-rings at both the rotor ends,
thus securing them against centripetal forces [1] on the rotor.
Damper windings are used to counteract an asynchronous air
gap flux which can be caused by electrical and mechanical
transients [2]. They are also used to bring up the motor to
synchronous speed in direct-online applications.
Due to the presence of flux harmonics in the airgap during
most of the times, the damper winding actively carries some
current. The harmonics can be categorized as space and time
harmonics [3]. Space harmonics is generated due to inherent
asymmetry of the rotor of the SM or the armature reaction
during different loading conditions, whereas time harmonics
can be attributed to the presence of the power electronic
devices, such as variable frequency drives (VFDs) [4]. All
these harmonics cause a varying magnetic field seen by the
rotor poles, consequently inducing a voltage in the damper
bars. The induced voltage is responsible for driving currents
in the damper winding. The currents give rise to magnetic
fields which are counteracting with the magnetic-field
harmonics [5]. A side effect of this process, however, is that
the current in the damper winding gives rise to resistive
losses.
S. Sahoo and P. Rodriguez are with ABB Corporate Research in
Västerås, Sweden (e-mail: subrat.sahoo@se.abb.com and
pedro.rodriguez@se.abb.com).
F. Holmgren is with Contec Control Technology AB, Sweden (e-mail:
fredrik.holmgren4@hotmail.com)
J. Perez and U. Lundin are with Department of Engineering sciences in
Uppsala university, Sweden (e-mail: Urban.Lundin@Angstrom.uu.se and
Jose.Perez@angstrom.uu.se).
978-1-5386-2476-0/18/$31.00 ©2018 IEEE
Damper windings are located on the outer edge of the
rotor. Therefore, if a damper bar breaks loose it could be
severely detrimental to the integrity of the entire rotor and
stator structure, with loose pieces potentially ending up in the
airgap region. Detection of the failed bars becomes difficult
due to the involvement of rotating instrumentation and a
means to involve sensor data acquisitions on to a stationary
surface, where further post-processing can be carried out [6].
An equivalent circuit representation for the current
flowing in the damper winding is illustrated in Fig. 1 [7], for
an SM with three damper bars per rotor pole. U1, U2, U3 are
the induced voltage in each damper bar, whereas Zi1 through
Zi4 with Zb represent the self and mutual inductance with
resistive losses of the damper winding circuit, before the field
current, enter and exit one pole (ii1 and ii4 respectively). The
damper bar currents can be calculated from this circuit to
register a failed bar compared to the healthy bar.
Fig. 1 – Damper winding circuit equivalent over one rotor pole having three
bars [7].
The reported literature concerning damper winding
failures are quite scanty due to that SMs with higher
megawatt (MW) ratings run critical application, hence the
confidentiality involved in the failure statistics made public is
rather high. A report [8] from 2015 examines a damper
winding failure of a large SM. This SM was used to drive a
compressor in a process industry. During maintenance,
serious damage to the damper windings was discovered.
Cracks were found at the point, where the damper bar
connects to the end-ring and some bars were totally
disconnected from the end-ring, as shown in Fig. 2.
As many as 25% of the damper bars were broken, by the
time the problem was first discovered in [8]. By investigating
the historical operation of the SM, it was concluded that
thermal stresses were the most probable causes of the
failures, but the conditions that lead to the failure is yet to be
ascertained. Moreover, the problem was discovered during
scheduled maintenance and therefore an early and preventive
failure detection mechanism is warranted to avoid such
incidents. One possible detection method proposed by the
authors is to monitor the amplitude of the stator winding
current. According to the findings of the report, the current is
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reduced in case of a damper winding failure. However, the demonstrated as a strong candidate for both stator and rotor
root cause for this reduction of amplitude could not be associated failure of SM [11].
ascertained from damper bar failures alone, therefore such Rotor field winding voltage has been evaluated for damper
investigation needs further validation of adopted fault bar failure indicator. In this method variations in the field
detection techniques. winding voltage are used to detect separation of the rotor
pole winding. The concept is based on cancellation of the
voltage difference between the segments at the no-fault
condition. If a bar is broken, a voltage difference between the
segments will occur. The study, presenting this method, was
restricted to two-pole turbo generators which have a different
field winding design, compared to salient-pole machines,
hence direct implementation on salient-pole machines is not
possible [12]. However, some conceptual ideas of the method
could possibly be applicable to salient-pole machines.
Another feasible method of fault detection can be done
using magnetic flux sensors in the air-gap. The sensors are
used to monitor the time-varying flux in the air-gap, when a
synchronous motor is started asynchronously, i.e. as an
induction motor. Damper bar failures are detectable since the
waveform characteristic of the air-gap flux is affected by the
damper winding [13].
The above literature sums up the fact that there are no
clear guidelines or indicators available for detecting a failed
damper winding that motivates the research in the appropriate
direction. The paper aims at addressing such a gap.
Remainder of the paper is based on the following aspects.
Section II offers a general description of the test setup that is
used for both simulation and experiments. Section III
Fig. 2 – Example of a broken damper winding which was discovered during
includes the finite element-based simulation for the healthy
maintenance of an SM. The bar has broken completely at the point where it and faulty condition of the damper bars. Section IV discusses
is connected to the end plate [8]. the procedures adopted for preparing the test setup, followed
by the subsequent data capture and analysis. The important
Failure of damper bar has some similarities with the outcome of the work is summarized in Section V, leading to
broken rotor bar for cage rotor induction motors (IMs). The the elaboration of the unfinished work.
SMs behave very similar to IMs during transient operations.
The sidebands of the stator current spectrum have visible II. GENERAL DESCRIPTION OF SYNCHRONOUS MACHINE
spectrum of rotor bar failure detection in case of IMs [9]. USED IN SIMULATION AND EXPERIMENT
In [10] a custom-built inside-out SM was used. The field
TABLE 1 FUNDAMENTAL DATA FOR THE SM.
winding was fed with DC located in the stator and three-
Nominal apparent power 75 kVA
phase AC was fed through slip rings to the armature winding
in the rotor. The damper bars were located on the stator side Power factor 0.9, leading
with easy access for fault simulation. However, the spectrum Stator voltage 156 V
of field current signature picked up the side bands even for Frequency 50 Hz
healthy damper windings, unlike a broken IM rotor bar. This Number of poles 12
is due to the asymmetric configuration of the damper winding
Number of phases 3
in the SM. Therefore, motor current signature analysis
(MCSA) cannot be considered as a complete technique for Number of damper bars 3
damper bar failure detection. Damper bar placement Asymmetric pitch
Normally damper winding is designed like an incomplete Nominal speed 500 rpm
IM rotor cage. Therefore, diagnostics of broken damper Number of stator slots 108
winding is far more complex compared to that of an IM. An
Stator inner diameter 725 mm
expression for the magnitude of left side band current, as a
function of the number of broken bars, is reported in [10], Stator length 393 mm
only during asynchronous operation of the SM. It also Air gap length 8.3 mm
reported higher stress for adjacent bars following a broken Stator winding type Concentric
bar that applies to both IMs and SMs, fed through VFDs. Stator winding connection Star
The inability of the stator current signatures for detecting
the damper bar failure pushes the researcher to look into the
A salient pole SM is used for analysis in this paper.
assessment made on the rotor side. The rotor has been

1790
Originally this particular SM was used commercially as a
motor with a rating of 185 kW at 380 V with a power factor
of 0.9. When the motor was taken out of service it was
donated to Uppsala University to be used for research
purposes. The motor has been rebuilt and installed in a
laboratory at Uppsala University. The vital information for
the SM is supplied in Table 1. The motor has been modified
with several accessible positions for introducing faults,
measurement, control and instrumentation purposes. A robust
structure holds the SM with the axis in a vertical position, as
shown in Fig. 3. The horizontal position of the stator is
adjustable while the rotor position is fixed. This
configuration allows re-dimensioning the eccentricity
distribution with respect to the airgap.
The rotor has a salient pole shape with laminated pole
shoes. Excitation of the field winding is carried out through
slip-rings. There are slots for three damper bars to be
integrated in each pole shoe. Damper bars and end-rings are
aligned with screws and nuts which make it possible to
remove single or multiple damper winding bars. The damper
bars in each pole has uneven separation distance with 1 and
1.2 stator slot pitches respectively. The distance
configuration is meant to support investigation of whether the
total harmonic distortion in the stator voltage is dependent on
the damper bar slot pitch [2].
Fig. 3 – Drawing of the SM used for experiments including the structure
which holds the machine, bearings, gearbox and induction machine. [2]
A general schematic of the connection of the SM is
presented in Fig. 4 for the laboratory setup. An IM is
connected to the SM through a right-angle gearbox with a
ratio of 3:1 (the rotational speed is three times higher for the
IM compared to the SM). The SM and the IM are both
connected to separate VFDs. This configuration makes it
possible to operate the SM as a motor or as a generator at
variable speed. The rating of the IM limits the maximum
1791
loading of the SM. It is also possible to connect the SM
directly to the grid or use resistors to load it when running in
generator mode. A restriction of the set-up is that the VFDs
are not regenerative. Consequently, power can only be feed
from the grid to the VFDs, but power cannot be fed to the
grid from the VFDs.
Fig. 4 – Schematic diagram of the lab setup. The two VFDs are represented
by the AC/DC-AC converters. The DC voltage source is feeding the field
winding of the SM through the slip-rings.
III. SIMULATION OF THE SM AND DAMPER BAR FAILURE
An in-house 2D finite element program [11], [7] is used to
describe the two-dimensional cross-sectional geometry of the
rotor of the SM. Table 1 in the previous section includes
some of the input parameters used for the model. The mutual
interaction of the magnetic circuit and the electrical circuit is
explained in detail in [7] and has been simultaneously solved
for the present SM, using an existing FEM model developed
by the research group [2]. The salient rotor pole with the
damper winding is divided into 72 segments as shown in Fig.
5. Every segment has an index which is indicating whether it
is a bar or a piece of the end-ring. The index also indicates
the position of the segment. Index 1-36 represent the 36
damper bars and index 37-72 represent the interconnections
between the bars which together form a complete end-ring.
The damper winding properties are changed to introduce
broken bar conditions. The current distribution is observed to
be disturbed following the broken damper scenarios. Nearly
no current is flowing through the broken bar, whereas the
current through the adjacent bars is increased. However, in
the end-ring segments which are connected to the broken bar,
the current is lowered.
Simulation of damper bar fault, however, requires
modeling of the entire machine. A small section of the
machine geometry obtained from the simulations is presented
in Fig. 6 with the rotor represented on the left part and the
stator on the right part, with the airgap separating the two.
Different colors were used to represent damper bars, field
winding, stator slots carrying armature windings, etc. The
failure of the damper bar could only be simulated in the form
of removal of a bar or modify the cross section the complete
bar since it is a 2D model. It was not possible to model the
crack of a damper bar, which could be a more realistic
situation. The magnetic flux density of the entire machine in
a 2D is presented in Fig. 7.

Fig. 5 Schematic drawing of damper bar used in the simulation.
Fig. 6 – Geometry showing a small cross-section and the mesh of one pole
with pole shoe, damper bars (orange), field windings (red), airgap (white),
stator slots, housing the stator armature windings (blue and green).
Fig. 7 – An example of the magnetic flux density of the machine.
1792
Simulations were carried out by feeding the stator of the
SM via purely sinusoidal or VFD supply separately. All the
simulations were performed at 50 Hz supply voltage, SM
running in motoring mode, loaded at 50% of the nominal
power. The sampling frequency is 10 kHz for sinusoidal and
20 kHz for VFD fed supply. The duration of every simulation
was 2s, which is enough to capture and overcome the
transient scenario, occurring at the start of the simulation. A
faulty damper winding was modeled by a suitable change of
the damper winding properties. The resistance of segment 17
(see Fig. 5) was changed from 0.64 to 20 ohms.
The comparison of VFD and sinusoidal fed stator winding
has been analyzed in detail in [3] for the stator current, as
well as for the current in the damper winding segment. The
root-mean-square (RMS) value of current in each segment is
higher when VFD supplied compared to sinusoidal supply, as
shown in Fig. 8, for the healthy damper bars. It can, however,
be noticed that the current distribution along the segments
follows a particular pattern in both VFD and sinusoidal
supply.
Fig. 8 – Current flowing through every individual damper winding segments
for the two different voltage supply types. The values presented are RMS-
values of the currents. The index structure is visualized in Fig. 5. Note that
the two diagrams do not have the same scale on the y-axes.
A. Broken damper bar detection during VFD supply
The RMS value of damper winding current calculated for
each segment is presented in Fig. 9 for healthy and a removed
damper bar condition for segment number 17. The consistent
pattern for the healthy damper winding is disturbed in case of
broken damper bar as can be clearly seen in the figure. The
missing bar registers no current. However, this has resulted in
an increase in current in the adjacent bars but at the same
time, the current in the end ring that connects the bars to the
other pole on either end have reduced in magnitude. This can
be noticed for segment number 52 and 55.
A time domain plot of the current in the pole of the
affected damper bar is given in Fig. 10, where the healthy
signatures (left plot) are compared with that of the broken bar
(right plot). The current through segment 52 is presented in
frequency-domain for the healthy and broken damper bar, in IV. EXPERIMENTAL INVESTIGATION
Fig. 11 and Fig. 12 for power and switching frequency This section entails the preparation for the damper
harmonics respectively. The dominating frequencies within winding current measurement on an existing setup that is
the range of the analysis are found only at relatively low explained in Section II. A special arrangement of hall sensors
frequencies, i.e. in Fig. 11. No frequency components above was made for the current measurement in the damper bars
1 kHz have an amplitude higher than 1 A. The 300 Hz (6th and its end ring of one pole. A series of operational
harmonic) component is the strongest one with an amplitude conditions were carried out. Specific measurement results are
of about 40 A. No significant differences are found when presented to signify the fault detection ability of the proposed
comparing the FFT of the currents for the healthy and the method through damper bar current. The slot harmonic
faulty case. amplitude influence, for instance, could be another valuable
indicator that has been reported in [2] and does not fall under
the scope of research for this work.

Figure 12 - Frequency content of the current flowing through end-ring

segment 52 (left) healthy and (right) segment 17 broken, shown up to 10
kHz. Refer to Fig. 5 for an explanation of the segment indexes.

A. Equipment to measure damper winding current

Fig. 9 - Currents in the damper winding segments. Refer to Fig. 5 for an
The damper winding currents are measured with a
explanation of the indexing. specially designed device used for measuring the damper bar
and end ring currents in one of the rotor poles. The device
Damper Winding Currents - for different segments in one pole was developed by the researchers in the hydropower research
16 - Bar 17 - Bar 18 - Bar 52 - Ring segment 53 - Ring segment 54 - Ring segment
group at Uppsala University for one of their research projects
100 100

80 Healthy 80
Broken bar [1]. By enclosing the three damper bars and the two pole
60 60
interconnectors using Hall-sensors it is possible to measure
40 40 the currents, as shown in Fig. 13. The three damper bars are
20 20 attached to the end-ring with washers and nuts. The two black
0 0 thick cables on each side of the device are the pole
-20 -20
interconnectors which are part of the end-ring. The sensors
are integrated in a structure which can be mounted in one of
-40 -40

-60 -60

-80
the poles. The damper bars, as well as the pole
-80

-100 -100
interconnectors, are slightly longer in dimension, in the pole
1430 1400 1405 1410 1415 1420 1425 1430
1400 1405 1410 1415
time [ms]
1420 1425
time [ms] where the current was measured, compared to the other poles
Figure 10 – Damper winding currents for the segments of one pole for the to facilitate this additional device. Different damper bar
case of VFD-supply. (left) healthy damper winding and (right) bar number connection configuration was tried for this setup [2]. The
17 is broken.
present investigation focuses on the damper windings with
interconnected pole arrangement. Five Hall-sensors are fed
with 10 V supply voltage coming via the slipring and the
output voltage is dependent on the current flowing through
the damper winding.
A rotating data acquisition (DAQ) system wirelessly
transfers the data to the stationary computer via an NI 9205
analog VI module. The damper bars were removed in
multiple locations along different poles to observe the
reflection on the currents under investigation. Different
operation speeds and frequencies were also tested. The RMS
value of current under steady state condition reported distinct
Figure 11 - Frequency content of the current flowing through end-ring behavior for the broken bar compared to the healthy
segment 52 for (left) healthy and (right) segment 17 broken, shown up to 1
kHz. Refer to Fig. 5 for an explanation of the segment indexes. condition.

1793
 and fifth harmonic component as the most dominant ones.
In Fig. 15, the RMS values of current through damper
winding segments for index number 16, 17, 18, 52 and 55 are
presented, where provision for damper winding current
measurement exists. A healthy damper bar present in index
17 is replaced with a partially broken bar, a cable of different
resistance and the bar was also removed to monitor their
impact on the measured current values on the affected bar as
well as on the other bars. The results confirm the current
profile observed in simulation (see Fig. 9). For the partial
broken bar case in the top right plot of Fig. 15, there is a
slight reduction in current for index 17, whereas current in
the adjacent bars (16 and 18) is amplified slightly. This
Figure 13 – Device used for measuring damper winding currents. observation is more prominent, however, in case of a missing
bar as well as the bar replaced with a cable, as seen in the
B. Experimental procedure for measurements at bottom left and right figure of Fig. 15 respectively.
different operational conditions
The choice of operations conditions for the SM is crucial
for the experiments since the operation must be
representative of a commercial SM. The SM was operated as
a motor, driven by a VFD at variable speeds. The only
loading was the mechanical loading from the drive chain of
the machine and friction due to windage. Consequently, the
machine was loaded at approximately 50 % of the nominal
power. The excitation current was set at a constant level.
From standstill, the SM was ramped up in speed
synchronously by controlling the frequency from the VFD.
Various configurations of the damper winding were tested
for different rotational speeds. First, some measurements
were performed with the healthy damper winding, in order to
get reference data. Then three different fault conditions were
tested. For all fault conditions, the central damper bar of one
Figure 14 Measured stator current at 50 Hz supply frequency (top) time
pole (pole#7) was modified. In one of the tests, a damper bar domain (bottom). The two components marked in the frequency domain are
was removed to simulate a bar which is completely broken. the fundamental frequency and the 5th harmonic.
Another condition was to have a cut halfway through the bar
to simulate a partially broken bar. In the third fault condition,
which was tested to verify the FEM-model, the bar was
replaced with a cable which had a smaller cross-sectional
area (3 mm) than the bar. Each damper winding condition
was tested at different speeds, ranging from 100 rpm to 500
rpm. All the data were captured at 10 kHz sampling rate.
The methods used for analysing the measurement data
varies for the different parameters. Alternating currents, such
as damper winding current and stator current were analysed
in time as well as frequency domain. By using this approach,
it is possible to detect deviations in the frequency spectrum
for the different damper winding conditions. Also, the RMS-
values of the damper winding currents were calculated and
compared with the results from the simulations. This was
done in order to verify the FEM-model.
Figure 15 – RMS-values of the currents in damper winding segment 16, 17,
C. Results from measurements 18, 52 and 55 for four different damper winding configurations. Refer to
Fig. 5 for an explanation of the segment indexes.
The most relevant operational point for the SM is at the
machine rated frequency, 50 Hz fed from the VFD supply The broken damper bar situation was repeated in different
during steady state condition. The results are presented for positions (middle and adjacent ones) of different poles.
such an operating condition. The stator current was measured Presence of more damper bars per pole could impact the
for the sake of completeness and is presented in Fig. 14 for sensitivity of the bar current under investigation. There could
both time and frequency domain in the top and bottom plot also be other factors such as skewed bars, damper bar
respectively. The frequency spectrum represents fundamental displacements, damper pitch ratio, type of materials, etc. that

1794
 could impact the analysis. The results were reported for a
specific case, due to the brevity of space.
V. CONCLUSION
The importance of the damper winding for the SM
operation was highlighted thus justifying a need for early
detection of the damper winding failures. A special hardware
was developed for the damper winding current measurement
in a specific pole. By monitoring the currents in the specific
and adjacent segments, it was possible to detect damper
winding faults during steady-state operation of an SM, driven
by a VFD. The current through a broken bar is reduced
compared to the healthy case, while the current in the
adjacent bars is increased. These experimental results are
supported by the simulation results.
Limited access to the damper bars for measuring the
current flowing through them, can still be addressed by
measuring the current in the rotor pole interconnections of
the damper winding. Through experiments and analysis of the
current in the interconnection segments, it was shown that
such an indicator can be promising. With the advent of
sophisticated current measurement techniques, it is possible
to install such hardware in new SMs. However, the practical
difficulties of implementing the concept as a retrofitted
solution still remain a challenge and need innovative
thinking.
The paper demonstrated a concept of measuring current in
the damper windings involved in one pole. A more detailed
damper bar model could be considered in future to account
for skin effect. This certainly paves way for current
measurements along the entire rotor poles that can
systematically address the localization of the damper bar
failure, with a corresponding mapping of the respective
segments. Operation of the SM as a generator might bring in
additional challenges while interacting with the grid that
needs further study for identifying and localizing the damper
winding failure. There is a host of opportunity that exists for
validating other potential indicators (such as airgap flux
sensors which can be readily present in all the poles) that can
detect damper bar failures.
VI. REFERENCES
[1] M. Wallin, "Measurement and modelling of unbalanced magnetic pull
in hydropower generators," Acta Universitatis Upsaliensis, Uppsala,
2013.
[2] M. Wallin, M. Ranlof, U. Lundin, "Design and construction of a
synchronous generator test setup," ICEM, Rome, Italy, 6-8 Sept. 2010.
[3] F. Holmgren, “Damper Winding Fault Detection in Synchronous
Machines,” Masters Thesis, Uppsala University, September 2016, PP
1-56.
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VII. BIOGRAPHIES
Subrat Sahoo (SM’ 17) obtained his PhD from Indian Institute of Science,
Bangalore in 2008. He is currently with ABB Corporate Research in
Sweden. His research interests include condition monitoring and diagnostics
of large electrical machines.
Fredrik Holmgren obtained his M.Sc. in energy systems engineering from
Uppsala University in 2016. He is currently a consultant at Contec Control
Technology AB. His expertise is within performance evaluation and
troubleshooting of electric powertrains.
Pedro Rodriguez obtained his Ph.D. degree from Helsinki University of
Technology (AALTO) in 2007. He is with ABB corporate research in
Sweden since 2008. His research interests lie in the field of design and
diagnostics of rotating electrical machines.
Jose Perez obtained his Ph.D. degree from Uppsala University in 2017. He
holds a researcher position with Uppsala University. His interests are
magnetic bearings and electrical machines.
Urban Lundin obtained his Ph.D. from Uppsala University in 2000. He
holds a professor position and heads the Hydropower group. His research
interests lie with merging modern power electronics and electrical machines.
He promotes the use of new emerging technologies and has worked in
several demonstration projects.