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MICADUR ® -COMPACT INDUSTRY Insulation System for Rotating Electrical Machines

AC Machines Voltages up to 15 kV Temperature class F (155°C)

INDUSTRY Insulation System for Rotating Electrical Machines AC Machines Voltages up to 15 kV Temperature class

The MICADUR ® -COMPACT INDUSTRY Insulation system

The MICADUR ® -COMPACT INDUSTRY (MCI) insulation system is based on the global Vacuum Pressure Impregna- tion (VPI) insulation method. The VPI method itself has successfully demon- strated its reliability for many years with machines used in all types of applications and has achieved world- wide recognition for excellence.

The MCI insulation system is applied to the entire range of form wound low and high-voltage AC machines pro- duced in ABB machine factories. This includes:

Motors with outputs between 0.1 and 50 MW Generators with outputs between 0.5 and 70 MVA Condensers with outputs between 2 and 50 MVAr Voltages up to 15 kV

with outputs between 2 and 50 MVAr Voltages up to 15 kV The MICADUR ® -COMPACT

The MICADUR ® -COMPACT INDUSTRY Insulation system has successfully demonstrated its industrial endurance for many years, achieving worldwide recognition for excellence.

MCI–Key Features

Excellent Reliability: Years of depend- able operational experience in a wide variety of applications has proven the excellent reliability of the system.

Proven System: Tens of thousands of machines with the MCI-system have been successfully in use by custom- ers all over the world throughout the years.

Outstanding Performance: The dedicated mica insulation combined with the global VPI process applying special epoxy resin ensure a long-life performance.

mica insulation combined with the global VPI process applying special epoxy resin ensure a long-life performance.

MCI–Properties

Careful design and controlled manu- facturing processes ensure that every stator winding with the MCI technique meets all relevant international stand- ards. Inspections and tests are con- ducted during the coil manufacturing and winding assembly to ensure a high quality for the final product.

Thermal stress

The thermal endurance capability of the MCI system has been proven by more than 30 years of operation under extreme conditions even with machines fully utilizing thermal class F tempera- ture rise. The thermal performance has been determined per IEEE Std. 434 and IEC 216-1 to 4 [1] by evaluating insula- tion properties over extended periods at temperatures ranging from 160°C to 200°C. Based on these criteria, the MCI system fully meets the requirements of Thermal Class F expressed in IEC 85 [2]. MCI insulated stators have also outstanding thermomechanical per- formance which has been confirmed in severe cycling tests and in various ap- plications even in arctic conditions.

Electrical stress

Each machine with MCI insulation system is tested in various production steps in order to ensure high reliabil- ity:

• Dimensional checks on insulated

coils to assure proper fit in the slots.

• Turn-to-turn insulation tests on each

individual coil prior to the VPI proc- ess.

• High potential tests of windings prior to VPI.

• Final high potential test of windings

after VPI at voltages according to inter-

national standards.

• Dissipation factor test according to CENELEC for periodical check of VPI and curing process parameters.

MCI meets all international standards for industrial machines

meets all international standards for industrial machines The MCI system has been extensive- ly type tested

The MCI system has been extensive- ly type tested in accordance with IEEE Std 434 [3] and IEC publ. 727-1 [4]. The results indicate a significant dielectric margin of safety according to IEEE Std. 1043 [5].

Standard designs utilizing MCI well exceed the international require- ments of impulse voltage capability as expressed in IEC 34-15 [6].

Ambient stress

Moisture: The penetration of epoxy resin in the coils, overhang supports and connections during the vacuum pressure impregnation process pro- duces a winding which is resistant to very severe ambient conditions. Further, as a standard option MCI windings can be provided sealed according to NEMA Std. 4, part 20.

Chemical Resistance: The materi- als used in the MCI insulation are re- sistant to acids and alkalines found in many industrial applications.

Flammability: The MCI system has proven to be virtually non-flamma- ble according to relevant IEC and ISO standards.

Radiation Resistance: All com- ponents of the MCI system exhibit a high resistance to radiation (at least 10 7 Gy) making machines with MCI insulation also suitable to nuclear ap- plications according to IEC 544 [7].

Mechanical stress

The excellent mechanical strength of the MCI coil overhang bracing enables the system to withstand re- petitive dynamic stresses of fast bus transfer (e.g. rapid auto reclosure) where coils may in the worst case be subjected to extremely high out- of-phase currents without damaging effects.

high out- of-phase currents without damaging effects. The high quality of the MICADUR ® -COMPACT INDUSTRY

The high quality of the MICADUR ® -COMPACT INDUSTRY system is assured by VPI

MCI–Structure and Manufacturing prior VPI

Tight compact construction

• The coils are made from insulated

conductor wires. Corona resistant polymer/mica combinations are used to ensure excellent turn to turn insulation.

• The form wound coils are

wrapped with porous mica tape to a thickness determined by the rated voltage to provide a durable ground wall insulation of high dielectric strength.

• Conductive corona protection

tape is applied on the stator slot portion of the coils to avoid corona

discharges in the stator slot.

• At higher rated voltages a semi-

conductive layer is applied to the coil overhang beginning at the slot

exit in order to achieve uniform stress grading of the voltage to ground.

• The unimpregnated soft coils are inserted in the stator slots.

• Highly resin absorbent fiberglass

cords are used for the coil overhang support. After vacuum-pressure impregnation (VPI) with epoxy resin, the support system forms an extremely rigid winding overhang structure being able to withstand the most severe service conditions.

• Slot wedges retain the coils firmly

in the stator slots. For asynchronous

machines magnetic slot wedges en- hance the power factor and operat- ing efficiency of the machine.

For asynchronous machines magnetic slot wedges en- hance the power factor and operat- ing efficiency of
For asynchronous machines magnetic slot wedges en- hance the power factor and operat- ing efficiency of

MCI–Impregnation Process

The vacuum pressure impregnation and curing of the completely wound and connected stator winding with the specially formulated epoxy resin en- sures a sealed and homogeneous insu- lation system, resulting in low dielectric losses, high dielectric strength, excel- lent heat transfer and the elimination of hazardous internal partial discharges.

Extensive research & development is the basis for ABB’s leadership in insu- lation technology
Extensive research
& development is
the basis for ABB’s
leadership in insu-
lation technology

Continuous Research and Development

ABB has traditionally maintained a leading position in developing insula- tion systems for rotating machines. The insulation R&D work is carried out in our well-equipped insulation laborato- ries, which in addition to actual insula- tion development are active in interna- tional cooperation and standardization.

Service and Maintenance of Windings

In general, MCI-windings require very little maintenance. Usually it is most important to prevent excess moisture and dirt from entering the machine. If the winding, however, has been damaged then several choices exist to put the machine back in operation:

1. In the case of minor damage, a partial repair using spare coils may be done. The spare coils are fabricated as individual coils and they are available on short notice. 2. In the case of widespread damage a complete rewinding is recommended, using the original MCI processing or a full set of replacement coils.

References

                                   

[1] IEC 216-1 of Electrical

to

4:

‘Guide

for the

Determination

of Thermal

Endurance

Properties

Insulating

Materials’

[2] IEC 85: “Thermal

Evaluation

and

Classifi

cation

of Electrical

Insulation”

[3] IEEE Std

434:

‘Guide

for

Functional

Evaluation

of Insulation

Systems

for Large

High Voltage

Machines’

[4] IEC publ. Systems’

727-1:

‘Evaluation

of

Electrical

Endurance

of

Electrical

Insulation

[5] IEEE Std.

1043:

‘Voltage

Endurance Testing

of

Form

wound

Bars

and Coils’

[6] IEC 34-15:

“Impulse Voltage

Withstand

Levels of

Rotating

A.

C.

Machines”

[7] IEC 544:

‘Guide

for

Determining

the

Effects

of Ionizing

Radiation

on

Insulating

Materials’

3BFP 001 980 R0101 REV B 06/2003

3BFP 001 980 R0101 REV B 06/2003 P ower is guaranteed even in most extreme conditions
3BFP 001 980 R0101 REV B 06/2003 P ower is guaranteed even in most extreme conditions
3BFP 001 980 R0101 REV B 06/2003 P ower is guaranteed even in most extreme conditions
3BFP 001 980 R0101 REV B 06/2003 P ower is guaranteed even in most extreme conditions

Power is guaranteed even in most extreme conditions all over the world by MICADUR ® -COMPACT INDUSTRY insulation system.

The information and specifications contained in this brochure are subject to change without notice.