Stator Insulation Aging andDesign for ReliabilityIRMC 2019New Orleans, LouisianaMay 7, 2019William Chen
Insulation Stresses andMachine Service Life- Electrical- MechanicalCrackingTensionVibrationInsul. SystemPDOvervoltageTracking- Thermal- ChemicalOxidationGas, AcidsRadiationHydrolysisnot easy to predictnot easy to testService Proof Methods
Motor Efficiency & Service Lifevs.Insulation DesignEL- Design QualityAcQ -------AsAc: total copper cross sectionAs: total slot cross sectiondA As -Ac Insulation filling20-40 yearsdA
Higher Corner E-Stress will cause lower PD Inception Voltageor earlier E-Failure
Turn To Turn Failure
Poor DesignSurface PD damages due to poorstress grading system
Design/Manufacture for Reliability toMinimize the Winding Aging Processes- Electrical- Thermal- Mechanical (Vibration, Movement)- Environment (Contamination: oil, dirt, water, chemical,salt, radiation .)- Manufacturing Process Issues- VFD operation
Basic Insulation Components in Large FormWound Motor Stator WindingsCOIL INSULATIONStrand/TurnInsulationDedicated TurnInsulation- Strand InsulationDaglass, Enamel,Kapton, Mica tape- Turn InsulationMica tape, or same asstrand insulation- Ground Wall Insul.Mica tape- Stress Grading SystemConducting coating;Semi-conducting coating
High Voltage Coil Voltage Stress Grading SystemFunctionTo smooth the voltagedistribution along the coilendturn (from HV to GND)Design ConsiderationsV- Non-Linear V-I charactersfor grading coating- Compatible betweenconducting/grading layers;- Proper design of the lengthand overlapping betweentwo layers;- Solid electrical contactsbetween two layers- Mechanical fatigue stress
Insulation Materials SystemsVacuum PressureImpregnation(VPI)- Mica tapes with low binderresin content (6-10%)- Solventless VPI resin(Epoxy or Polyester)Resin-RichRR- Mica tapes with highbinder resin content(37 -45%)
Good VPI’ed CoilPoor VPI’ed Coil
Basic Insulation Components in LargeForm Wound Motor Stator WindingsWINDING INSULATION- Coil lead joints insulationMica Tape- Main lead (cable) insulationSilicon Rubber- Leads & cable spacersFelt & Micarta
Coil BracingWedges & Top FillersSide Fillers
Design Limits of Winding Insulation Allowance- Strand Insulation: Withstand 120 V AC test voltage;- Turn Insulation: Based on actual winding electrical designand operating voltage stress at Surge Voltage Condition:NEMA std./IEEE std. 522:Typical: 2 p.u.Severe: 3.5 p.u.- Ground Wall Insulation:Typical: 50 – 70 Volts/Mil (single side)Some designs: 100 Volts/MilMfg Process and Material Dependent
16AC break down in kV14Single Wall insulationthickness in milsMils10kV1268420123456Insulation types78AC breakdown strength in kV and single wallinsulation thickness in mils for different turninsulation systems9101. Heavy film enamel2. SDG & heavy filmenamel3. DDG & heavy filmenamel4. Single layer halflapped Kapton5. Single layer halflapped mica tape6. Double layer of edgelapped mica tape7. Single layer edgelapped mica tape overheavy film enamel8. Double layer edgelapped mica tape overheavy film enamel9. Single layer halflapped mica tape oversingle layer half lappedKapton10.Double layer halflapped Kapton
75 gm, single PET filmComparison of AC breakdown voltage of mica taped wirestested at various conditions (4 suppliers)
Effect of Coil Shape Design (Aspect Ratio) on theInsulation StressE-StressD/W 5D/W 10
Various Insulation Qualification Tests IEEE 275 & 429 (new 1776) for thermal classification.IEEE 1043 & 1553 for high voltage ( 4 kV) endurance.IEEE 1310 for thermal cycling.IEEE 1434 for PD (partial discharge).Thermal and voltage endurance.Darkness test for stress grading materials.Water immersion test for moisture resistance.IEEE 286 for power factors tip-up test.IEC 60034-18-41,42 for inverter drive application.Other IEC standards.
Strain Measurement at 3 phases S. C. fault
Thermography of Stress Control System EvaluationSGO high frequencySame Peak voltage 20.1 kV60 HzBNCBNCGrounding plates
Partial Discharge Analysis26 kV and above machinesCcPhase VoltagePDA
ConclusionAdvanced Materials/Designs andManufacturing TechnologiesHelpto Improve the Stator WindingInsulation Quality and Service Life
Questions?Comments?
IEEE 275 & 429 (new 1776) for thermal classification. IEEE 1043 & 1553 for high voltage ( 4 kV) endurance. IEEE 1310 for thermal cycling. IEEE 1434 for PD (partial discharge). Thermal and voltage endurance. Darkness test for stress grading materials. Water immersion test for moisture resistance.
stator coil/ Double-sided AFPM brushless machine with three-phase, 9 -coil external salient-pole stator and 6-pole internal rotor. 1 - PM, 2 - stator backing ferromagnetic disc, 3 - stator pole, 4 - stator coil. Coreless multidisk AFPM machine with three coreless stators and four PM rotor units: 1 - stator winding, 2 -
Mechanical Insulation Pipe, Tank and Equipment Insulation Micro-Flex Large Diameter Pipe & Tank Insulation Micro-Lok HP Pipe Insulation Micro-Lok Pipe Insulation Spin-Glas 800 Series Duct & Equipment Insulation Spin-Glas 1000 Series High Temperature Equipment Insulation Insulation for Rectangular Steel Ducts Linacoustic RC Duct Liner
Aging Facility (AP) Foundation Design 170-DBC-AP00-00100-000-00A 1. PURPOSE The purpose of this calculation is to perform a preliminary foundation design for aging pad 17P, shown in 170-P10-AP00-00102-000, Aging Facility General Arrangement Aging Pad 17P Plan (Reference 2.2.2), and for aging pad 17R, shown in 170-P10-AP00-00103-000, Aging Facility
DESIGN OF ELECTRICAL MACHINES UNIT - IV D. RAJASEKARAN ASSOC.PROF./EEE 2. Choice of specific electricloadings DESIGN OF STATOR 1. Statorturns/phase S m WS E S 4.44 fK Turns/phase T m P and B av DL 2. Area of statorconductors S S Area of each stator conductor a I S S - 4-S 3E Stator current per phase I Input kVA Current density in stator .
8.2.1.1 Stator of Three Phase Induction Motor The stator of the three phase induction motor consists of three main parts :. i. Stator Frame It is the outer most part of the three phase induction motor. Its main function is to support the stator core and the field winding. It acts as a covering and it provide
A progressive cavity pump is a rotary positive displacement pump which consists of a spiral shaped rotor that moves eccentrically inside the stator. The stator has the shape of an internal gear with one tooth more than the rotor, and it is made of rubber often, the rotor coated with chrome is made of steel usually [3].
MSC Software 22 Overview of Electric Motor Noise (1) Magnetic noise is usually generated by the interaction of electromagnetic flux waves with the resonant frequencies of stator core or teeth The shape (usually round) of the stator lamination structure is deformed by imbalance in radial the force vectors The stator-frame (or stator-enclosure) structure is the primary radiator of .
FOAMULAR XPS ROOF INSULATION FOR COMMERCIAL BUILDINGS PAGE 5 FOAMULAR XPS ROOF INSULATION FOR COMMERCIAL BUILDINGS FOAMULAR XPS insulation is a rigid foam insulation which meets the needs of today’s design professionals for a truly sustainable insulation product. Owens Corning insulatio