a variety of frequenciestransformer testing at the Pittsfield
plantjuly/august 2010IEEE power & energy magazine
75historyThomas J. BlalockDigital Object Identier
10.1109/MPE.2010.937132TTHEFACTORYTESTINGOF large power
transformers during the early 20th century was complicated by
thefactthatmanysuchtransformers
weredesignedforoperationonfre-quencies other than 60 Hz. This meant
that adequate levels of power had to be available at several
frequencies for the
accuratedeterminationofthetrans-formercoreloss(noloadloss).Inad-dition,poweratmuchhigherfrequen-cies
was needed to test the integrity of
thetransformerinsulationstructureat voltage levels signicantly
higher than the operating voltage. An elaborate power plant was
devel-oped during the early 1900s to provide test power at a
variety of frequencies at theformerlargetransformerplantof the
General Electric (GE) Company in Pittseld, Massachusetts (see
Figure 1).Direct Current (dc) Drive
MotorsThetechniqueemployedatthePitts-eldplant(andelsewhereaswell)to
obtainthenecessarytestpoweratthe variety of frequencies needed to
deter-mine transformer core loss was to drive
thealternatingcurrent(ac)generators supplying power to the test
berths with dc motors.Duringtheearly20thcentury, five different
power system frequen-cies that had been introduced at
vari-oustimesduringthe1890swerein more or less common use. These
in-cluded 25 Hz (introduced atNiagara Thomas Blalocks history
article in the March/April issue of IEEE Power & Energy
Magazine covered the dramatic display of high-voltage discharges
presented at the GE Company exhibit at the 1939 New York Worlds
Fair. This issues
offer-ing,alsoauthoredbyTom,sharesacommonsettingwithhisearlierarticlethe
western Massachusetts city of Pittsfield, the largest municipality
in and the county seat of Berkshire County.William Stanley
established a transformer manufacturing business in Pitts-field in
1891. The Stanley Electric Manufacturing Company was acquired by GE
intheearly1900s,and,by1907,thegrowingcomplexoffactoryandsupport
buildings that comprised the Pittsfield plant were being commonly
referred to as the Pittsfield Works. For most of the 20th century
and up until final closure of the transformer line in the late
1980s, Pittsfield was GEs prime site for the manufacture of large
high-voltage transformers. For many years, the Pittsfield plant
employed thousands of workers and was consistently the largest
employ-er in the Pittsfield
area.TheGEHigh-VoltageEngineeringLaboratorywasestablishedatthePitts-fieldplantin1914,anditwastherethattheawe-inspiring,high-voltagedis-chargedisplayspresentedatthe1939WorldsFairweredevelopedandper-fected.
In this new article, Tom offers our readers a fascinating insight
into the process of large transformer testing at Pittsfield and the
need for test power at
variousfrequenciestoproperlydeterminesuchparametersascorelossand
insulation integrity. This is the 11th history article that Thomas
J. Blalock has authored and con-tributed to IEEE Power & Energy
Magazine. Tom earned a B.S.E.E. degree from Lafayette College and
an M.E.E.E. degree from Rensselaer Polytechnic Institute. His
duties as a development engineer at the former GE High-Voltage
Engineer-ingLaboratoryinPittsfieldincludedlightningprotectionandhigh-voltage
switching surge studies. Toms retirement hobby continues to be the
explora-tion and careful documentation of historically important
and interesting elec-tric power projects and equipment. His long
experience at the Pittsfield plant uniquely qualifies him to author
this issues history
article.WearepleasedandhonoredtowelcomeTombacktothesepagesasour
guest history author for this issue of IEEE Power & Energy
Magazine.Carl SulzbergerAssociate Editor, History76IEEE power &
energy magazinejuly/august 2010Falls),30Hz(introducedbythe
WestinghouseElectricCompany), 40Hz(introducedbyGE),50Hz
(usedinsouthernCaliforniaandin Europe),andthesurvivingstandard of
60 Hz.In the Pittseld test power
installa-tion,threemotor-generatorsetswere
usedtoconverttheavailable60-Hz powerintheplantintodcpowerat
vedifferentvoltages.Thesewere 220,275,330,440,and550V.Each
dcdrivemotorcouldbeoperatedon oneofthesevevoltages.Thetest
generatorthatitdrovewouldthenbe operatedataspeedsuitabletoallow
ittoproduceoneoftheveneeded frequencies.Finespeedcontrolwas
available to the test berth operators by means of drive-motor eld
rheostats in the berths (see Figure 2).Since the primary function
of these test generators was to provide power at
theproperfrequencyfortheaccurate measurement of transformer core
loss (no-load loss), the generators were
of-tenreferredtointhateraasmagne-tizers. This term reected the fact
that onlymagnetizingcurrenthadtobe supplied during the core loss
measure-mentprocedure.Thegeneratorshad
signicantlygreaterkVAratingsthan necessaryforthispurpose,however.
Thishelpedtoinsurethatthewave-formoftheacvoltageappliedtothe
transformerduringthecorelosstest wouldbeasclosetoatruesinewave as
possible. Anotherreasonfortherelatively high kVA ratings of these
test genera-tors was the fact that they were
some-timesusedtoprovidecurrentduring
thetransformerloadlosstest(short circuittest).Thegeneratorswere
equippedwithmultisectionwindings thatcouldbeconnectedinvarious
congurations. This allowed low volt-age at high current to be
obtained. The winding connections were changed by
meansofexternallinkboardsaccord-ingtostandardlinkarrangementdia-grams
posted nearby.Frequency ChangersSomemotor-generatorsetsinthistest
powerinstallationconsistedoftwoac synchronous machines coupled
togeth-er.Theseservedthepurposeofcon-verting the available 60-Hz
plant power into higher-frequency power necessary to test the
insulation structures of trans-formers at voltages signicantly
higher than their designed operating voltages. figure 1. Postcard
view of the main gate of the Pittsfield GE Company plant in 1913
(image courtesy of Berkshire Athenaeum, Pittsfield,
Massachusetts).figure 2. Early test berth control panel with motor
and generator field rheostat control wheels beneath desk (photo
courtesy of the Hall of Electrical History, Schenectady, New
York).78IEEE power & energy magazinejuly/august
2010Itisnotpossibletoapplyavoltage signicantlyhigherthanthe
operating voltageofatransformerbecausethis
woulddrivethemagneticcoreinto saturation. Faradays law, the basic
law of electromagnetic induction, relates the quantity volts per
turn in a transformer to the rate of change of the magnetic ux in
the core. If a higher than normal volts per turn is imposed on the
transformer at its normal operating frequency,
Fara-dayslawrequiresthatmaximumux
densityinthecoreincreaseinpropor-tion.Thiswouldsaturatethecore,and
normaltransformeroperationwould cease. If, however, the transformer
is ex-cited at a frequency signicantly higher
thanitsdesignfrequency,therateof
changeofuxwouldincreaseinpro-portion. This allows the maximum ux
density to remain near its normal level,
whileFaradayslawisstillsatisedat much higher values of volts per
turn.Suchahigh-voltageinsulationtest is referred to as an induced
test because the higher-than-normal voltage applied
isinducedbytransformeractioninto all of the windings. This, then,
tests the integrityoftheturn-to-turninsulation structure of the
transformer.Earlyinthe20thcentury,itwas decided that a frequency
about 400 Hz wouldbesatisfactoryforthemajority of such induced
tests. Accordingly, two large 420-Hz motor-generator sets were
installedinwhichthegeneratorhad seventimesthenumberof magnetic
poles as did the 60-Hz drive motor. In addition, a 200-Hz
motor-generator set wasinstalledforspecialapplications
inwhichthe420-Hzfrequencywould createobjectionablecapacitiveeffects
inthetransformerundertest.Thisset consisted of a six-pole drive
motor and two 20-pole generators.Heat RunsA heat run is a long-term
test in which the ultimate temperature rise inside the transformer
is determined. In the years during which the power installation
de-scribed here was in use, it was possible to conduct heat run
tests with the trans-former both excited at its rated voltage and
carrying rated current in its wind-ings. Such tests required the
use of two generators.Amagnetizerwasusedto
exciteonewindingatratedvoltage (which would then be induced by
turns ratiointotheotherwindings)whilea
secondgenerator,commonlycalleda loader,wouldservetocirculaterated
current in the windings.Forrelativelysmalltransformers, such a heat
run could be performed by using the loader to return the required
kVA (mostly reactive) to the power
sys-tem.Thiswascalledaloadingback heat run, but it required the
magnetizer tohavethecapacitytosupplythefull kVA of the transformer
under test.Since the vast majority of
transform-ersbuiltduringthiseraweresingle phase with three units
(and sometimes a fourth as a spare) being used for
three-phaseapplications,itwasnormalto have duplicate transformers
available in the shop. One single-phase transformer
couldbegivenaheatrunbyconnect-ing it with one of its duplicates in
such a way that the magnetizer generator was required to supply
only the magnetizing current while the loader generator
sup-pliedratedcurrent,ataveryreduced
voltage,whichcirculatedinthewind-ings of both transformers. This
was re-ferred to as a bucking heat run.Eventually,however,aslarger
transformers were built, such heat runs figure 3.A 60-cycle loader
with dc drive motor in the foreground and workers assembling
switchboard panels in the left background (photo courtesy of the
Hall of Electrical History, Schenectady, New York).figure 4.
Postcard view of the Pittsfield plant from the southeast, circa
1915, with Building 12 at right center (image courtesy of Berkshire
Athenaeum, Pittsfield, Massachusetts).80IEEE power & energy
magazinejuly/august
2010werenolongerfeasible.Accord-ingly,theindustryrecognizedthe
acceptanceofwhatwastermeda compromise heat run in which only
ratedcurrentatreducedvoltage was circulated in the windings of a
short-circuited transformer. In this typeofheatrun,thecontribution
ofthecoreloss(atratedvoltage) to the heating of the transformer is
simulated by holding a total loss in kilowatts (core loss plus load
loss) untilthe temperatureoftheoilin the transformer stabilizes at
its ulti-mate temperature rise value.Since a great many
transformers weredesignedforoperationat25
Hzduringtheearly20thcentury, averyunusualmotor-generator set was
included in this test power installation,whichwasusedas
aloaderforheatrunson25-Hz transformers.Thisconsistedof
a60-Hzdrivemotorcoupledtoa large(3,100kVA)generatorthat produced
24-Hz power. Experience withbuckingheatrunsoverthe years had shown
that it was actually desirable to offset the frequency of the
loading current slightly from the frequencysuppliedbythemagne-tizer
generator. The latter frequency hadtobeheldatthepropervalue
toaccuratelyexcitethecoreloss, buttheloaderfrequencycouldbe varied
slightly with no detrimental effectsontheaccuracyofthetest. The use
of a 24-Hz loader generator greatly simplied the design of the
loadermotor-generatorsetoperat-ing from 60 Hz (to generate 25-Hz
power, this set would have required a 24-pole drive motor). This
set was called the 24-cycle loader.Allofthefrequencychang-er
motor-generatorsetswere figure 5. One of several switchboard
sections for the control of test generators (photo cour-tesy of the
GE Company).CAPEs dynamicTCC display makes it easy to see how
coordination time intervals change when you move the fault
around.Realistic models:Detailed bus structuresWorlds largest
library of detailed,vendor-specific relay modelsCurrent-limited
wind generatorsFor serious work:Automated relay-setting
Stepped-event simulations Automated coordination checking,wide area
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softwareSoftwareTrainingConsultingCustomersThe protection engineers
productivity secret1-888-240-4044 (US only)
1-734-761-8612www.electrocon.com/pes82IEEE power & energy
magazinejuly/august 2010 controlledfromonesetofslate
switchboardpanels.Sincethemajor machineswerethe420-Hzinduced
testgeneratorsandthe24-Hzloader
generator,thisswitchboardwasinter-estingly referred to on drawings
as the 24 & 420-cycle Board.Later,asmoretransformerswere
beingbuiltforoperationat60Hz, anotherlargegenerator(4,300kVA)
wasinstalledandwasreferredtoas the60-cycleloader.Thissetwas
equipped with a dc drive motor so it ac-tually could be driven at
various speeds toloadheatrunsatfrequenciesother
than60Hz.Theuseofeldrheostat control on the drive motor allowed for
theslightoffsetofloadingfrequency, if necessary (see Figure 3).The
Pittsfield
InstallationThiselaborateinstallationofmotor-generatorsetsandswitchboardswas
located in the westernmost bay of what wasknowninthePittseldplantas
Building12,whichdatedfrom1914 (seeFigure4).Themotor-generator
section was called the power bay.figure 6. Early view of the
Pittsfield plant power house interior (photo courtesy of the Hall
of Electrical History, Schenectady, New York).84IEEE power &
energy magazinejuly/august 2010The plant itself, however, dated
from 1900. The original buildings were
con-structedasanewhomefortheStan-leyElectricManufacturingCompany,
which had been located since 1891 in a much smaller facility near
the center of Pittseld.WilliamStanleyiscredited with having
demonstrated the rst suc-cessful use of transformers for ac
dis-tribution in 1886 in the town of Great
Barrington,Massachusetts,southof Pittseld.Atthattime,Stanleywas
workingforGeorgeWestinghousein Pittsburgh,Pennsylvania.Following
thisdemonstration,however,Stanley decidedtoleaveWestinghouseand
start his own transformer
manufactur-ingbusinessinPittseld.TheStanley
CompanywaslateracquiredbyGE, and, by 1907, the Pittseld plant
facili-ties had become known collectively as the Pittseld Works of
GE.The Stanley Company had
construct-edatestpowerfacilityintheoriginal building of the
Pittseld plant (Building 1) and, in 1914, many of the
motor-gen-erator sets there were moved to the new
powerbayinBuilding12.Othersets were built at that time by GE in
that com-panys Schenectady, New York, plant. The power bay extended
380 ft (116 m)fromnorthtosouthandwas40ft (12.2 m) wide. A good
portion of both the east and west wall areas of the bay
containedswitchboardpanelsforthe
controlofthevariousrotatingma-chines. As was common practice in
that era, these were slate panels mounted on iron pipe frameworks
(see Figure 5).Atthenorthendofthebaywere three motor-generator sets
that convert-ed the 60-Hz plant power (at 2,300 V) to the ve
different dc voltages needed to drive the test generators at
different speeds. There were four dc generators
inallsinceonemotordrovetwogen-erators. These sets were referred to
as the prime movers since they served to provide the primary power
for the op-eration of the test generator
sets.Theacdrivemotorsforthesesets, aswellasthoseofthefrequency
changersets,weretwophaserather than three phase because, at that
time, the plants power house was equipped
withtwo-phasegenerators.Thiswas aleftoverfromtheStanleyCompany
era.Stanleymanufacturedtwo-phase
generators,inadditiontotransform-ers, during the 1890s. This
resulted be-cause both GE and Westinghouse were producing
three-phase generators then, andStanleysadherencetotwo-phase
machineslessened(butdidnotcom-pletely eliminate) patent conicts
with theothercompanies(seeFigure6). Remnants of this two-phase
power sys-tem were actually still in use when the Pittseld GE plant
ceased operations in 1987. The remaining two-phase equip-ment in
the plant was supplied from a three-phasepowersystemusingspe-cial
phase-conversion transformers.Atthenorthendofthepowerbay,
thefourprimemovergeneratorspro-vided a total of 1,900 kW of dc
power at ve voltages. Three 100-kW exciter
motor-generatorsetsfedthemain 125-Vdcexciterbusthatsuppliedthe elds
of the majority of the test
genera-torsandtheirdcdrivemotors.Inad-dition,therewere14smallerexciters
dedicatedtocertainofthelargergen-erators.The
totalavailableexcitation power was 720 kW (see Figure 7).There were
a total of 16 two-phase ac drive motors for variousmotor-generator
figure 8. The power bay from the south end with step-up
transformers in pits in the foreground (photo courtesy of the Hall
of Electrical History, Schenectady, New York).figure 7. The power
bay from the north end with an operator seated at a desk near the
center of the image (photo courtesy of the Hall of Electrical
History, Schenectady, New York).86IEEE power & energy
magazinejuly/august 2010sets that totaled over 5,200 hp.
Twenty-threedcdrivemotors,totaling6,570
hp,droveatotalof29testgenerators (six motors drove two generators
each). Thesegenerators totaledover14,000 kVA with the largest
having a capacity of 1,500 kVA each. In addition, a
940-hpdcmotordrovethe60-cycleloader generator (see Figure
8).Besidesthetestgenerators,there wereatotalofeightgeneratorsdriven
by ac motors for high-voltage testing and
24-Hzloading.Thisbroughtthetotal number of machines (motors plus
gener-ators) in the power bay to 99. There was also one spare
induction motor listed in themachineinventory.Thisraisedthe grand
total of machines to exactly 100.Unusual
EventsOccasionally,therewasaneedfor 180-Hzpowertoconductspecial
high-voltageinducedtests.Thisfre-quency was not normally available
in the power bay. Accordingly, the drive motor for one of the
420-Hz induced test motor-generator sets was
tempo-rarilydisconnectedfromitsnormal 60-Hzsupplyandwasreconnected
tooneofthelargetestgenerators.
Thedcdrivemotorforthatgenera-torwasthenoperatedattheproper voltage
to allow the generator to pro-duce 25-Hz power. This would allow
theinducedtestmotor-generatorset toprovide175-Hzpowerinsteadof
420-Hzpower.Byweakeningthe fieldofthedcdrivemotorslightly,
the25-Hztestgeneratorwouldbe speeded up and the required 180-Hz
powerthencouldbeobtainedfrom the induced set.The test generators
were three-phase machines.Todrivethetwo-phasemo-tor of the induced
test set, a special two-phase link diagram was used on the test
generatortoobtaintwo-phasepower. The load on the generator had to
be kept belowitsratingduetotheunbalanced nature of this
connection.The unintentional weakening of the
eldofadcdrivemotorcould,how-ever, lead to disastrous results since
it causes the motor to speed up. This did occur on one occasion in
the 1950s.Priortothis,someofthelarger
testgeneratorsetshadbeenequipped withAmplidynecontrolsforboththe
generatoreld(toaccuratelycontrol outputvoltage)andthemotoreld(to
accurately control speed). This method
madeuseofsmallAmplidynecontrol generators driven by an ac motor.
One ofthetestgeneratorsetssoequipped was located in the southern
half of the powerbay,anditsdcdrivemotorwas fed from what was named
the dc motor board in the northern half of the
bay.Itwasafairlylongwalkfromthe locationofthistestgeneratorsettothe
dc motor board, and asecond-shift fore-manhaddevelopedan
unconventional Fault Locators from5 36kV760 3200JHVI is the source
for both VLF withstand testing and cable fault location on all
sizes of power cable and collector cables used on wind farms,
especially for 33 kV and 35 kV cable circuits. Portable Substation
and Switchgear hv test equipment available also. Buy individual
productsor let us design a complete VLF cable care test &
locate package.ISO 9001 : 2008july/august 2010IEEE power &
energy magazine 87If you participate in the FTR (CRR/ TCC)
market,you know that developing competitivetransmission-rights
bidding strategies andportfolios is critical to your success.Thats
where Nexants HEDGEcan help.As the industrys only comprehensive
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with:All the power and flexibility needed forsimulating and
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auctionsHEDGE package capabilities include:All auction timeframes
(month, season,year, etc.)Peak, off-peak, 24-hour, and
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all new FTRproductsAre you an FTR/CRR/ TCCmarket
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[email protected]://www.nexant.com/products/erms_hedge.htmlHEDGEThe
comprehensive multifunctionFTR/CRR/TCC auction package.technique
for shutting down this set at the end of his shift. He would simply
trip out the adjacent Amplidyne set. This would
removetheeldsupplyforthedcdrivemotor,andtheset
wouldbegintospeedup.Thatwouldcausetheover-speed
deviceonthesettofunctionandtripthemotorarmature breaker on the
distant dc motor board, thus shutting down the set. This foolhardy
method worked ne until one fateful night when the over-speed device
operated properly, but the arma-ture breaker failed to trip. The
motor-generator set speeded up
beyondcontrolinaveryshorttimeanddestroyeditselfina spectacular
manner.Fortunately, nobody was injured in this debacle, but the
wall of the power bay adjacent to the former motor-generator set
had to be completely rebuilt. A subsequent inventory of power bay
machines facetiously listed this motor-generator set as being in
orbit (see Figure 9).EpilogueBy the 1920s, the presence of 30- and
40-Hz electric power in the United States had declined signicantly,
so transform-ers were rarely built for use on these frequencies.
Therefore, the need for dc drive motors on transformer testing
genera-tors
diminished.AtPittseld,auniquetestgeneratorsetwasinstalledin
1925.Thisconsistedoffourlargemachinesplusastarting motor. Two of
the machines were 12,000-kVA test generators
thatcouldbeparalleledforthetestingofverylargetrans-formers. The set
was equipped with two synchronous ac drive
motorsaswell,whichwereusedoneatatime.Onemotor drove the set at a
speed that allowed the generators to produce 60-Hz power for
testing. Even though 60-Hz power was
avail-ableforthedrivemotors,theuseofageneratorfor60-Hz testing
allowed for accurate control of the test voltage.The other drive
motor was equipped with sectional con-sequent-polewindings. These
windings could beconnected
tooperatethemotorataspeedthatallowedthegenerators
toproduce50-Hzpower.Byreconnectingthemotorwind-ings to effectively
double the number of magnetic poles, this figure 9. The remains of
the self-destructed motor-genera-tor set (photo courtesy of Roy
Himes).88IEEE power & energy magazinejuly/august 2010same motor
would operate at one-half normalspeedtoallowthegenerators
toproduce25-Hzpower.Thismotor-generatorsetwassolargethatitwas
housedinabuildingadjacenttothe powerbayandcametobereferredto
bythetestdepartmentsimplyasthe bigset.Itremainedinuseuntil1966 when
it was scrapped to make way for newconstruction.Thesethadbeen
abusedovertheyearsbecauseitwas
sometimesusedtoconductshortcir-cuittestsontransformersatfullrated
voltagetodeterminethemechanical stressesonthewindingsduringshort
circuit conditions.Theoccasionalneedfor25-and
50-Hztestpoweractuallyremained untilthenalclosingofthePittseld
transformerplantin1987.Twenty-veHzfurnacetransformersforthe
powering of large electric-arc furnaces in steel plants continued
to be built in Pittseldasmanyoldersteelplants were still using
25-Hz power systems. Also,duringtheearly1980s,50-Hz transformers
were built in Pittseld for shipment to both Egypt and Israel. One
of the old dc drive test motor-generator sets had been kept in
usable conditiontoaccuratelymeasurecore loss for such transformers.
It was used,
however,veryinfrequently.Accord-ingly,therststepofthewrittenin-structions
for starting up this set was to notifytheplantredepartment.This was
necessary since the dust
accumu-latedonthesetwouldtriggerthead-jacent smoke detector as the
machines warmedup.Thedcpowerrequired
tooperatethissetwasobtainedfrom amodernsolid-staterectierunitin
later years.In the 1960s, new induced test
gen-eratorswereinstalledthatoperatedat
afrequencyof240Hz.Occasionally, however,specialinducedtestshadto
beconductedattheold420-Hzfre-quency, and one of the old induced
test motor-generatorsetsinthepowerbay
wouldbestartedupforthispurpose. This occurred for the last time in
1983. Overall, this fascinatingly complex ar-ray of motor-generator
sets in the pow-er bay served to provide test power for 70
years.Today,Building12stillstands, butallofthepowerbayequipmentis
longgoneexceptforacollectionof lerecords,machinenameplates,and
switchboardmeterssalvagedandpre-served by the author. For Further
ReadingT.J.Blalock,TransformersatPitts-field.Baltimore,MD:GatewayPress,
1998.W. T. Taylor, Transformer Practice. New York: McGraw-Hill,
1913.InstructionsforTestingElectrical
Apparatus.Schenectady,NY:General Electric Company, 1941. p&eE x
p e r t s Te a c h i n gf r o m P r a c t i c a lE x p e r i e n c
eWh y K i n e c t r i c s ? Expert knowledge and know-how Practical
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