Advances In

Generator Field Ground Protection

Using Digital Technology

Charles J. Mozina, Member, IEEE

Abstract: Advances in digital technology have provided relay BRUSH

FIELD
designers with the tools to increase the capabilities of modern +
generator relays. This allows more sophisticated protection
functions to be added to digital relays to provide better generator
protection within a single relay hardware platform. Functions FIELD
EXCITER BREAKER
such as field ground fault detection and brush lift-off detection
are two examples of such relay functions. This paper discusses
field ground protection using an injection method recently
incorporated into a multifunction digital generator relay. The -
scheme presented in this paper addresses field ground GROUNDING
BRUSH BRUSH
detection on generators with brushes and an external source
of dc field current and voltage. It has been installed on over Fig. 1 Basic Generator Field Circuit
150 generators. Though many of today’s new generators are
brushless, there still exists a large population of older
generators where the scheme described in this paper is In the method shown in Fig. 2, a dc voltage source in series
applicable. Developed and used in Europe for many years, the with an overvoltage relay coil is connected between the nega-
scheme lends itself to digital technology and offers many tive side of the generator field winding and ground. A ground
advantages over currently used field ground dc voltage methods. anywhere in the field will cause the relay to operate. A brush is
used to ground the rotor shaft since the bearing oil film may
Index Terms: Multifunction Digital relay, field ground, brush insert enough resistance in the circuit so that the relay would
lift-off, injection method, real-time monitoring, stray bearing not operate for a field ground. One to three seconds of time
current. delay is normally used with this relay in order to prevent un-
necessary operations for momentary transitory unbalances
I. INTRODUCTION of the field circuit with respect to ground. These momentary
unbalances may be caused by the operation of fast-response,
The field circuit of a generator is an ungrounded (typically thyristor-type excitation systems.
600 V) dc system, as shown in Figure 1. A single field ground
fault generally will not affect the operation of a generator nor Fig. 3 illustrates a second method used to detect field circuit
will it produce any immediate damaging effects. However, the grounds. It is similar to ground detection schemes used to
probability of a second ground fault occurring is greater after sense grounds on substation control batteries. This method
the first ground fault has occurred because field insulation has
deteriorated and the first ground has established a ground ref- BRUSH
erence. When a second ground fault occurs, a portion of the FIELD
+
field winding will be short-circuited, thereby producing unbal-
anced air gap fluxes in the machine. These unbalanced fluxes
produce unbalanced magnetic forces which result in machine FIELD
EXCITER BREAKER
vibration. A field fault also produces rotor iron heating from the
unbalanced short circuit currents. The tripping practices within
BRUSH
the industry for field ground relaying are not well established.
Some users trip while others prefer to alarm, thereby risking a -
second ground fault and major damage before the first ground 64F GROUNDING
BRUSH
is cleared. The existing practice within the industry had been to VOLTAGE
RELAY
use dc voltage relaying to detect field ground faults. These
DC
schemes are illustrated in Fig. 2 and Fig. 3.

Fig. 2 Field Ground Detection Using a dc Source

BRUSH FIELD BREAKER
+ ground relays depicted in Fig. 2 and Fig. 3. Therefore, the alarm
VARISTOR
R1
GENERATOR
FIELD
64F EXCITER
VOLTAGE
RELAY
R2
TEST PUSH BUTTON
(OPTIONAL)
FIELD BREAKER
-
BRUSH
Fig. 3 Field Ground Detection Using a Voltage Divider
uses a voltage divider and a sensitive overvoltage relay
between the divider midpoint and ground. A maximum voltage
is impressed on the relay by a ground on either the positive or
negative side of the field circuit. However, there is a null point
between positive and negative where a ground fault will not
produce a voltage across the relay. This generator field ground
relay is designed to overcome the null problem by using a non-
linear resistor (varistor) in series with one of the two linear
resistors in the voltage divider. The resistance of the varistor
varies with the applied voltage. The divider is proportioned so
that the field winding null point is at the winding midpoint
when the exciter voltage is at rated voltage. Changes in exciter
voltage will move the null point from the field winding center.
Both these voltage schemes have been prone to false operation—
especially during unit start-up. Unit operators would routinely
reset the alarm and continue with start-up procedures. If a
persistent alarm occurred, operators attempted to locate the
problem. If the ground could not be found within a reasonable
time, the unit was supposed to be tripped manually. However,
the many nuisance alarms and the very few legitimate ones
caused some unit operators to lose confidence in the field
lost credibility. Operators continued to keep the units on-line,
hoping that a second ground would not occur. Catastrophic
rotor failures have occurred due to a second ground in the field
developing very quickly after the first ground. In these
instances, the operators were not able to isolate the cause of
the first alarm nor were they able to bring the units off-line in an
orderly fashion before the second ground occurred.
II. INJECTION FIELD GROUND PROTECTION
Clearly, a more secure field ground relay is desirable if auto-
matic tripping is being considered. Such a relay is shown in Fig.
4 and uses an injection principle. This principle has been widely
used in Europe with great success, but until recently, it was not
available in a multifunction digital relay. As illustrated in Fig. 4,
a ±15 volt square wave signal is injected into the field through
a coupling network. The return signal waveform is modified
due to its field winding capacitance. The injection frequency
setting is adjusted (0.1 to 1.0 Hz) to compensate for field wind-
ing capacitance. From the input and return voltage signals, the
relay calculates the field insulation resistance.
The ±15V square wave signal is fed into a coupler circuit.
The purpose of the coupler circuit is to isolate the high dc field
voltages from the square wave signal amplifier. The coupler
circuit, designed with only passive components, injects the
square wave signal into positive and negative terminals of the
generator field winding. The rotor earth resistance and the cou-
pler series resistance divide the injected square wave signal
like a voltage divider. The voltage proportional to the rotor
earth resistance is fed back by the coupler into the multi-
function digital relay. This square wave voltage signal is ac
coupled to block the dc voltage and is isolated using an isolation

Generator Multifunction Relay

Coupler Circuit
Injection
Digital
Signal
Processor
Square Wave
Generator ± 15V.
Isolation &
Amplification
Signal
+ Brushes
GEN.

-
ROTOR

Measurement
Analog Isolation Signal (Vf )
Subsystem Amplifier

Machine
See Fig. 7 Frame
Ground
Fig. 4 Field Ground Protection Using an Injection Voltage Signal
 Voltage across the rotor earth resistance (Vf)
Rotor earth resistance, R (K ohms)
Fig. 5
amplifier. The analog subsystem samples this signal and
converts it to a digital signal using an analog-to-digital converter.
The injection frequency is made programmable and is
selected by the user based on the rotor capacitance. This gives
more accurate measurement of the rotor earth resistance and
minimizes the errors due to rotor capacitance charging time.
The gain of the isolation amplifier and its associated circuit is
not linear. Field measured test data was used to construct the
model shown in Fig. 5. It can be seen from this figure that the
non-linearity can introduce large errors in the measurement
of rotor earth resistance. A piece-wise quadratic approximation
to the gain characteristic is implemented within the relay for a
resistance measurement range of 5k to 100k ohms. The earth
resistance (R) is given by the equation below:
R=A()+A1Vf+A2Vf2
Where A() A1 and A2 are the polynomial coefficients which
are obtained using a least-squares approximation technique for
each of the segments. Vf is the injection voltage measured
across the rotor earth fault resistance. The resulting measure-
ment errors, after the above approximation, are within 10%.
The relay setpoints are in ohms typically with a 20 KΩ alarm
and 5 KΩ trip or critical alarm. The injection scheme provides a
major improvement over traditional voltage schemes in terms
of both sensitivity as well as security. In addition, digital relays
can provide real-time monitoring (Fig. 6) of field insulation re-
sistance so deterioration with time can be monitored. The scheme
can also detect grounds on an off-line generator allowing the
Nonlinear Gain Characteristic Model
operator to determine that the field circuitry is free of a ground
before start-up. The above described injection scheme cannot
be used as a second scheme in conjunction with existing volt-
age schemes described in Fig. 2 and Fig. 3. These voltage
schemes interfere with the injection voltage field ground method.
III. BRUSH LIFT-OFF DETECTION
The use of the injection method for field ground detection pro-
vides a means of detecting how well the brushes of a generator are
making contact with the rotor shaft. This is done by analyzing the
return voltage signal. Brushes on older generators are a constant
maintenance headache for plant personnel. If brushes open on an
in-service generator, they can cause substantial arcing damage to
the brush mounting structure and eventually result in unit tripping
by loss of field protection. Knowing when brushes should be
replaced or readjusted is important diagnostic information for plant
maintenance personnel. Relay monitoring that provides such infor-
mation can greatly reduce the changes of brush open circuit during
generator operation. Analysis of the return voltage signal (Vf) within
the injection field ground relay can provide an indication that the
brushes on a generator are not making good contact with the rotor.
Fig. 7 shows the method used to analyze the return voltage
signal. The front of the return voltage signal is rounded due to
the field winding capacitance. When the brushes begin to open,
the capacitance seen by the injection signal reduces, and the
return signal will rise very quickly. The level of voltage is mea-
sured at a fixed point on the return voltage signal (Vf). The
voltage is measured during each square wave cycle. When the
voltage rises above its normal level for a suitable time, an alarm

Fig. 6 Field Ground Fault Protection— Real Time Measurements
is initiated to alert the operator that the brushes should be
inspected. The lower the field circuit capacitance, the less of a
voltage rise occurs. For field capacitance of 0.5 µF or less, the
brush lift-off voltage will not rise enough to allow the scheme
to operate properly. This is a very low value of capacitance not
typical of most generators. A high brush contact resistance
also prevents the injection signal from entering the field wind-
ings, impairing the field ground resistance measurement. The
brush lift-off voltage will also rise if the ground brushes on the
generator begin to open. If the ground brushes are allowed to
open, the only path to ground for stray ground current is
through the machine bearings. Fig. 8 illustrates this point. Sus-
tained current flow through the generator bearings will result in
pitting and will require the bearing to be changed.
IV SETTING & COMMISSIONING
To date, well over 150 digital injection field ground relays
have been installed on generators of all sizes as well as prime
movers (steam, gas turbines and hydro). The settings and
commissioning time have been greatly reduced through the
use of real-time metering, which allows data measured by the
relay to be used in the commissioning process. The field ground
coupler is typically installed at a convenient point where the
positive and negative of the field and machine frame ground are
available. The installation location is typically at the excitation
cubicle. Shielded cable is used to connect the coupler to the
Brush Lift-
Off Voltage
Field Insulation
Real-Time
Monitoring
relay. Fig. 9 illustrates the basic connections. For long-shielded
wire runs between the coupler and the relay, errors can be
introduced in the field insulation measurement. To overcome
this problem, the relay software allows calibration to compen-
sate for the long wiring runs. A decade box is connected as
shown in Fig. 10. The decade box resistance is varied from 1-
100 KΩ. The software guides the user in selecting the proper
decade box resistance.
The injection frequency is programmed per the table shown
in Table 1. The injection frequency is based on the field wind-
ing to ground capacitance. In most applications, the shunt
capacitance is measured with a standard capacitance meter.
The metering screen in the relay (Fig. 6) provides a real time
measurement of field ground insulation. As a final test on a
de-energized generator, the decade box is connected from
positive or negative to frame ground simulating a field ground
fault. The generator field breaker is closed. Grounds ranging
from 5-50 KW are simulated with the decade box and read
through the relay metering screen. Accuracy is ± 10%, or ±1
KW—whichever is larger.
The brush lift-off feature provides the means to detect how
well the brushes on a generator are making contact with the
rotor. This is an alarm feature to alert the operator that the
machine brushes (positive and negative or ground) are not
making good contact with the rotor. Typically for healthy
 VALARM
Voltage Rise
Due to Brush Resistance
VNORMAL Increasing

Brush OPEN GROUND BRUSH

Lift-Off
Voltage GENERATOR TURBINE
(Vf)
BEARING BEARING BEARING

STRAY GROUND CURRENT

Measurement Point Time

VNORMAL= Normal Voltage Fig. 8 Stray Bearing Ground Current

for Healthy Brush Contact
VALARM = Alarm Voltage
when Brush Resistance
Increased due to
Poor Contact

Fig. 7 Brush Lift-Off Voltage

brushes, the value of brush lift-off voltage is measured using V. CONCLUSIONS

the relay metering screen shown in Fig.6. The alarm setting is
typically set at about 110% higher than the normal healthy brush
level. During commissioning, the full open circuit brush voltage
can be determined by opening the positive and negative inputs
to the coupling network (terminals 2 and 3 in Fig. 9) or opening
the ground terminal (terminal 1 in Fig. 9) The brush lift-off
voltage setting should be below this voltage valve.
The advances in digital technology have provided relay
designers with the tools to increase the capabilities of modern
digital relays to provide more complete protection of generators.
Important protective functions such as reliable field ground fault
and brush lift-off detection can now be added to the normal
complement of generator relaying. These functions are key
protective areas on generators.

Exciter

PROTECTIVE RELAY + _

Squarewave 3 Brushes
Vout
Generator Gen.
Rotor
Vin
Return Signal 2
Measurement
Coupling
Vf Network

GROUND
GND
1

Shield

Ground/Machine Frame

Fig. 9 Typical Field Ground Connection Diagram

 PROCESSOR

Field Ground
Detection

Squarewave Vout 3 Shorted during calibration. Remove

Generator before placing into service.
Coupling
Network 2
Signal
Measurement Rf
Vf
and
Processing
1

Decade Box or Discrete Resistor

To simulate Fault Resistance

Fig. 10 Field Ground Calibration

VI. REFERENCES VII. BIOGRAPHY

[1] “Fundamental Reliability Considerations in the Design, Charles J. Mozina is Applications Man-
Manufacturing and Application of Multifunction Digital Relays
for Generator Protection,” Charles J. Mozina and Murty Yalla, ager for Beckwith Electric Co. He is respon-
Canadian Electric Association, April 1996. sible for the application of Beckwith prod-
[2] “IEEE Guide for AC Generator Protection,” ANSI/IEEE C37.102- ucts and systems used in generator pro-
1995. tection and intertie protection, synchro-
[3] “IEEE Tutorial on the Protection of Synchronous Generators,”
IEEE 95TP102, July 1995. nizing and bus transfer schemes.

Chuck is an active member of the IEEE

Field Winding to Typical Power System Relay Committee and is the
past chairman of the Rotating Machinery Subcommittee. He
Ground Capacitance Frequency Setting is active in the IEEE IAS I&CPS committee which addresses
1 µF 0.52 Hz industrial system protection. He is a former U.S. representa-
tive to the CIGRE Study Committee 34 on System Protection
2 µF 0.49 Hz and chairs a CIGRE working group on generator protection.
He also chaired the IEEE task force which produced the tuto-
3 µF 0.46 Hz rial “The Protection of Synchronous Generators,” which won
4 µF 0.43 Hz the PSRC’s 1995 Outstanding Working Group Award. Chuck
is the 1993 recipient of the PSRC’s Career Service Award.
5 µF 0.39 Hz
Chuck has a Bachelor of Science in Electrical Engineering
6 µF 0.35 Hz from Purdue University and has authored a number of pa-
pers and magazine articles on protective relaying. He has
7 µF 0.32 Hz over 25 years of experience as a protective engineer at
8 µF 0.30 Hz Centerior Energy, a major investor-owned utility in Cleve-
land, Ohio where he was the Manager of the System Protec-
9 µF 0.28 Hz tion Section. He is also a former instructor in the Graduate
School of Electrical Engineering at Cleveland State University
10 µF 0.26 Hz as well as a registered Professional Engineer in the state of
Table 1 Typical Frequency Settings Ohio.