Table of Contents

Cover

Series

Title Page

Copyright

Preface

Chapter 1: Rotating Machine Insulation Systems

1.1 Types of Rotating Machines

1.2 Winding Components

1.3 Types of Stator Winding Construction

1.4 Form-Wound Stator Winding Insulation System Features

1.5 Random-Wound Stator Winding Insulation System Features

1.6 Rotor Winding Insulation System Components

References

Chapter 2: Evaluating Insulation Materials and Systems

2.1 Aging Stresses

2.2 Principles of Accelerated Aging Tests

2.3 Thermal Endurance Tests

2.4 Electrical Endurance Tests

2.5 Thermal Cycling Tests

2.6 Nuclear Environmental Qualification Tests

2.7 Multifactor Stress Testing

2.8 Material Property Tests

References

Chapter 3: Historical Development of Insulation Materials and Systems

3.1 Natural Materials for Form-Wound Stator Coils

3.2 Early Synthetics for Form-Wound Stator Coils

3.3 Plastic Films and Non-Wovens

3.4 Liquid Synthetic Resins

3.5 MICA

3.6 Glass Fibers

3.7 Laminates

3.8 Evolution of Wire and Strand Insulations

3.9 Manufacture of Random-Wound Stator Coils

3.10 Manufacture of Form-Wound Coils and Bars

3.11 Wire Transposition Insulation

3.12 Methods of Taping Stator Groundwall Insulation

3.13 Insulating Liners, Separators, and Sleeving

References

Chapter 4: Stator Winding Insulation Systems in Current Use

4.1 Consolidation of Major Manufacturers

4.2 Description of Major Trademarked Form-Wound Stator Insulation Systems

4.3 Recent Developments for Form-Wound Insulation Systems

4.4 Random-Wound Stator Insulation Systems

References

Chapter 5: Rotor Winding Insulation Systems

5.1 Rotor Slot and Turn Insulation

5.2 Collector Insulation

5.3 End Winding Insulation and Blocking

5.4 Retaining Ring Insulation

5.5 Direct-Cooled Rotor Insulation

5.6 Wound Rotors

5.7 Superconducting Sychronous Rotors

References

Chapter 6: Rotor and Stator Laminated Cores

6.1 Magnetic Materials

6.2 Mill-Applied Insulation

6.3 Lamination Punching and Laser Cutting

6.4 Annealing and Burr Removal

6.5 Enameling or Film Coatings

6.6 Stator and Rotor Core Construction

References

Chapter 7: General Principles of Winding Failure, Repair and Rewinding

7.1 Failure Processes

7.2 Factors Affecting Repair Decisions

7.3 Rapid Repair of Localized Stator Winding Damage

7.4 Cutting out Stator Coils After Failure

7.5 Bar/Coil Replacement and Half Coil Splice

7.6 Rewinding

References

Chapter 8: Stator Failure Mechanisms and Repair

8.1 Thermal Deterioration

8.2 Thermal Cycling

8.3 Inadequate Resin Impregnation or Dipping

8.4 Loose Coils in the Slot

8.5 Semiconductive Coating Failure

8.6 Semiconductive/Grading Coating Overlap Failure

8.7 High Intensity Slot Discharge

8.8 Vibration Sparking (Spark Erosion)

8.9 Transient Voltage Surges

8.10 Repetitive Voltage Surges Due to Drives

8.11 Contamination (Electrical Tracking)

8.12 Abrasive Particles

8.13 Chemical Attack

8.14 Inadequate End Winding Spacing

8.15 End Winding Vibration

8.16 Stator Coolant Water Leaks

8.17 Poor Electrical Connections

References

Chapter 9: Round Rotor Winding Failure Mechanisms and Repair

9.1 Thermal Deterioration

9.2 Thermal Cycling

9.3 Abrasion Due to Imbalance or Turning Gear Operation (Copper Dusting)

9.4 Pollution (Tracking)

9.5 Repetitive Voltage Surges

9.6 Centrifugal Force

9.7 Operating without Field Current

9.8 Remedies

References

Chapter 10: Salient Pole Rotor Winding Failure Mechanisms and Repair

10.1 Thermal Deterioration

10.2 Thermal Cycling

10.3 Pollution (Tracking and Moisture Absorption)

10.4 Abrasive Particles

10.5 Centrifugal Force

10.6 Repetitive Voltage Surges

10.7 Salient Pole Repair

References

Chapter 11: Wound Rotor Winding Failure Mechanisms and Repair

11.1 Voltage Surges

11.2 Unbalanced Stator Voltages

11.3 High Resistance Connections-Bar Lap and Wave Windings

11.4 End Winding Banding Failures

11.5 Slip Ring Insulation Shorting and Grounding

11.6 Wound Rotor Winding Repair

References

Chapter 12: Squirrel Cage Induction Rotor Winding Failure Mechanisms and Repair

12.1 Thermal

12.2 Cyclic Mechanical Stressing

12.3 Poor Design/Manufacture

12.4 Repairs

References

Chapter 13: Core Lamination Insulation Failure and Repair

13.1 Thermal Deterioration

13.2 Electrical Degradation

13.3 Mechanical Degradation

13.4 Failures Due to Manufacturing Defects

13.5 Core Repairs

References

Chapter 14: General Principles of Testing and Monitoring

14.1 Purpose of Testing and Monitoring

14.2 Off-Line Testing Versus On-Line Monitoring

14.3 Role of Visual Inspections

14.4 Expert Systems to Convert Data into Information

References

Chapter 15: Off-Line Rotor and Stator Winding Tests

15.2 DC Hipot Test

15.3 Polarization/Depolarization Current (PDC)

15.4 DC Conductivity

15.5 Poor Connection Hot Spot (High Current-Infrared Camera)

15.6 AC Hipot

15.7 Capacitance

15.8 Stator Capacitance Tip-Up

15.9 Capacitive Impedance Test for Motor Stators

15.10 Dissipation (or Power) Factor

15.11 Power (Dissipation) Factor Tip-Up

15.12 Off-Line Partial Discharge for Conventional Windings

15.13 Off-Line Partial Discharge for Inverter-Fed Windings

15.14 Stator Blackout and Ultraviolet Imaging

15.15 Stator Partial Discharge Probe

15.16 Stator Surge Voltage

15.17 Inductive Impedance

15.18 Semiconductive Coating Contact Resistance

15.19 Conductor Coolant Tube Resistance

15.20 Stator Wedge Tap

15.21 Slot Side Clearance

15.22 Stator Slot Radial Clearance

15.23 Stator End Winding Bump

15.24 Stator Pressure and Vacuum Decay

15.25 Rotor Pole Drop (Voltage Drop)

15.26 Rotor RSO and Surge

15.27 Rotor Growler

15.28 Rotor Fluorescent Dye Penetrant

15.29 Rotor Rated Flux

15.30 Rotor Single-Phase Rotation

References

Chapter 16: In-Service Monitoring of Stator and Rotor Windings

16.1 Thermal Monitoring

16.2 Condition Monitors and Tagging Compounds

16.3 Ozone

16.4 Online Partial Discharge Monitor

16.5 Online Capacitance and Dissipation Factor

16.6 Endwinding Vibration Monitor

16.7 Synchronous Rotor Flux Monitor

16.8 Current Signature Analysis

16.9 Bearing Vibration Monitor

16.10 Stator Winding Water Leak Monitoring

References

Chapter 17: Core Testing

17.1 Knife

17.2 Rated Flux

17.3 Core Loss

17.4 Low Core Flux (El-CID)

References

Chapter 18: New Machine Winding and Rewind Specifications

18.1 Objective of Stator and Rotor Winding Specifications

18.2 Trade-Offs Between Detailed and General Specifications

18.3 General Items for Specifications

18.4 Technical Requirements for New Stator Windings

18.5 Technical Requirements for Insulated Rotor Windings

References

Chapter 19: Acceptance and Site Testing of New Windings

19.1 Stator Winding Insulation System Prequalification Tests

19.2 Stator Winding Insulation System Factory and On-Site Tests

19.3 Factory and On-Site Tests for Rotor Windings

19.4 Core Insulation Factory and On-Site Tests

References

Chapter 20: Maintenance Strategies

20.1 Maintenance and Inspection Options

20.2 Maintenance Strategies for Various Machine Types and Applications

Reference

Appendix A

A.1 Insulation Material Tables

Appendix B

B.1 Insulation System Tables

Index

Series

End User License Agreement

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Guide

Table of Contents

List of Illustrations

Figure 1.1

Figure 1.2

Figure 1.3

Figure 1.4

Figure 1.5

Figure 1.6

Figure 1.7

Figure 1.8

Figure 1.9

Figure 1.10

Figure 1.11

Figure 1.12

Figure 1.13

Figure 1.14

Figure 1.15

Figure 1.16

Figure 1.17

Figure 1.18

Figure 1.19

Figure 1.20

Figure 1.21

Figure 1.22

Figure 1.23

Figure 1.24

Figure 1.25

Figure 2.1

Figure 2.2

Figure 2.3

Figure 3.1

Figure 4.1

Figure 6.1

Figure 6.2

Figure 6.3

Figure 6.4

Figure 6.5

Figure 7.1

Figure 7.2

Figure 8.1

Figure 8.2

Figure 8.3

Figure 8.4

Figure 8.5

Figure 8.6

Figure 8.7

Figure 8.8

Figure 8.9

Figure 8.10

Figure 8.11

Figure 8.12

Figure 8.13

Figure 8.14

Figure 8.15

Figure 8.16

Figure 8.17

Figure 8.18

Figure 8.19

Figure 8.20

Figure 8.21

Figure 9.1

Figure 9.2

Figure 9.3

Figure 9.4

Figure 10.1

Figure 10.2

Figure 10.3

Figure 10.4

Figure 10.5

Figure 11.1

Figure 11.2

Figure 11.3

Figure 12.1

Figure 12.2

Figure 12.3

Figure 12.4

Figure 12.5

Figure 12.6

Figure 12.7

Figure 12.8

Figure 12.9

Figure 13.1

Figure 13.2

Figure 13.3

Figure 13.4

Figure 13.5

Figure 13.6

Figure 13.7

Figure 13.8

Figure 13.9

Figure 13.10

Figure 13.11

Figure 13.12

Figure 15.1

Figure 15.2

Figure 15.3

Figure 15.4

Figure 15.5

Figure 15.6

Figure 15.7

Figure 15.8

Figure 15.9

Figure 15.11

Figure 16.1

Figure 16.2

Figure 16.3

Figure 16.4

Figure 16.5

Figure 16.6

Figure 16.7

Figure 16.8

Figure 16.9

Figure 16.10

Figure 16.11

Figure 16.12

Figure 16.13

Figure 16.14

Figure 16.15

Figure 16.16

Figure 16.17

Figure 16.18

Figure 16.19

Figure 16.20

Figure 17.1

Figure 17.2

Figure 17.3

Figure 17.4

Figure 17.5

Figure 17.6

Figure 17.7

Figure 17.8

Figure 17.9

Figure 17.10

Figure 17.11

Figure 17.12

Figure 17.13

Figure 17.14

Figure 17.15

Figure 17.16

Figure 17.17

Figure 17.18

Figure 17.19

Figure 17.20

Figure 17.21

Figure 18.1

Figure 18.2

Figure 18.3

Figure 18.4

Figure 18.5

Figure 18.6

Figure 18.7

Figure 18.8

Figure 18.9

Figure 18.10

Figure 18.11

Figure 18.12

List of Tables

Table 2.1

Table 2.2

Table 2.3

Table 2.4

Table 6.1

Table 7.1

Table 15.1

Table 15.2

Table 15.3

Table 15.4

Table 16.1

Table 16.2

Electrical Insulation for Rotating Machines

Design, Evaluation, Aging, Testing, and Repair

Second Edition

Greg Stone

Ian Culbert

Edward A. Boulter

Hussein Dhirani

Copyright © 2014 by The Institute of Electrical and Electronics Engineers, Inc.

Published by John Wiley & Sons, Inc., Hoboken, New Jersey. All rights reserved

Published simultaneously in Canada

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Library of Congress Cataloging-in-Publication Data is available.

Electrical insulation for rotating machines : design, evaluation, aging, testing, and repair / Greg C. Stone, Ian Culbert, Edward A. Boulter, Hussein Dhirani. – Second edition.

pages cm

Includes bibliographical references and index.

ISBN 978-1-118-05706-3 (cloth : alk. paper) 1. Electric insulators and insulation. 2. Electric machinery–Windings. 3. Electric motors. 4. Electric machinery–Protection. I. Stone, Greg C., editor. II. Culbert, Ian, editor. III. Boulter, Edward A., editor. IV. Dhirani, Hussein, editor.

TK3401.E424 2014

621.31′042–dc23

2014021677

Preface

This edition was updated by two of us, Greg Stone and Ian Culbert. Given the developments in rotating machine insulation in the past decade, readers will see expanded information on the effect of drives on insulation, the addition of a number of relatively new failure mechanisms, and new diagnostic tests. Many more photos of deteriorated insulation systems have been added in this edition. Many more references have been added, and recent changes in IEEE and IEC standards have been incorporated. We have also added descriptions of the insulation systems used by Chinese and Indian machine manufacturers. The information on Chinese systems came from Mr. Yamin Bai of North China EPRI. Mr. Bai and his colleagues were also responsible for the Chinese version of the first edition of this book. New appendices were added, which give detailed information on the insulation systems used by many manufacturers, as well as insulation material properties. These tables first appeared in a US Electric Power Research Institute (EPRI) document that is long out of print. However, given the number of machines still using these systems and materials, we thought it will be useful to include the information here.

We again would like to thank our spouses, Judy and Anne, and also our employer, Iris Power L.P. We are also grateful to Ms. Resi Zarb for help in organizing and editing the second edition. Finally, we thank the readers of the first edition who took time to point out errors and omissions in the first edition.

Greg Stone and Ian Culbert

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