MICADUR -COMPACT INDUSTRY Insulation System for Rotating Electrical Machines

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

The MICADUR -COMPACT INDUSTRY Insulation system

The MICADUR-COMPACT INDUSTRY

(MCI) insulation system is based on the global Vacuum Pressure Impregnation (VPI) insulation method. The VPI method itself has successfully demonstrated its reliability for many years with machines used in all types of applications and has achieved worldwide recognition for excellence. The MCI insulation system is applied to the entire range of form wound low and high-voltage AC machines produced 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

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

MCIKey Features

Excellent Reliability: Years of dependable 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 customers 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.

MCIProperties

Careful design and controlled manufacturing processes ensure that every stator winding with the MCI technique meets all relevant international standards. Inspections and tests are conducted during the coil manufacturing and winding assembly to ensure a high quality for the final product.
Thermal stress

MCI meets all international standards for industrial machines

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 temperature rise. The thermal performance has been determined per IEEE Std. 434 and IEC 216-1 to 4 [1] by evaluating insulation properties over extended periods at temperatures ranging from 160C to 200C. 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 performance which has been confirmed in severe cycling tests and in various applications even in arctic conditions.
Electrical stress

Each machine with MCI insulation system is tested in various production steps in order to ensure high reliability:
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 process. High potential tests of windings prior to VPI. Final high potential test of windings after VPI at voltages according to international standards. Dissipation factor test according to CENELEC for periodical check of VPI and curing process parameters.
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The MCI system has been extensively 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 requirements 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 produces 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 materials used in the MCI insulation are resistant to acids and alkalines found in many industrial applications. Flammability: The MCI system has proven to be virtually non-flammable according to relevant IEC and ISO standards. Radiation Resistance: All components of the MCI system exhibit a high resistance to radiation (at least 107 Gy) making machines with MCI insulation also suitable to nuclear applications according to IEC 544 [7].

The high quality of the MICADUR

Mechanical stress

-COMPACT INDUSTRY system is assured by VPI

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

MCIStructure 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 semiconductive 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 enhance the power factor and operating efficiency of the machine.

MCIImpregnation Process
The vacuum pressure impregnation and curing of the completely wound and connected stator winding with the specially formulated epoxy resin ensures a sealed and homogeneous insulation system, resulting in low dielectric losses, high dielectric strength, excellent heat transfer and the elimination of hazardous internal partial discharges.

Extensive research

Continuous Research and Development

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

& development is the basis for ABBs leadership in insulation technology

ABB

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 to 4: Guide for the Determination of Thermal Endurance Properties of Electrical Insulating Materials [2] IEC 85: Thermal Evaluation and Classication of Electrical Insulation [3] IEEE Std 434: Guide for Functional Evaluation of Insulation Systems for Large High Voltage Machines [4] IEC publ. 727-1: Evaluation of Electrical Endurance of Electrical Insulation Systems [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

Power is guaranteed even in most

extreme conditions all over the world by MICADUR-COMPACT INDUSTRY insulation system.

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

3BFP 001 980 R0101 REV B 06/2003