Higher MVA High Voltage Turbine Generator Stator Winding with Multi

Turn Coils for Global Vacuum Pressure Impregnation - Design Development,

Engineering Automation and Manufacture
P.G.S. Kumar
Additional General Manager,BHEL,Hyderabad
Email: pgskumar@bhelhyd.co.in

Abstract
Multi turn coils utilizing Global Vacuum
Pressure Impregnation (GVPI) technology for solid
dielectric insulation of high voltage armature
windings in the range of 20 to 35 MVA rating turbine
generator is well established practice and number of
machines are successfully operating in power sectors.
This paper presents design development and
manufacture of higher capacity machine in 4 pole
category with multi turn diamond pulled coils to meet
the power needs of industrial sectors. Design
methodology,
automation
of
engineering
documentation and manufacture techniques with state
of art dielectric insulation technology has been
described. Technical features, dielectric requirement
of higher inter turn voltages and slot fill are briefed..
Experience on sample coil manufacture and test
results of vacuum pressure impregnated coil are
shared. Type tests result on proto type windings and
performance observations have been detailed. Merits
over the single transposed bar type windings are
highlighted.

Key words:
Dielectric insulation system, multi turn coils,
global vacuum pressure impregnation, roebel bar,
turbine generator.

1. Introduction:
Multi turn diamond pulled coils of high voltage
armature windings with resin poor fine mica taped
insulation in the range of 20 to 35 MVA capacity
turbo generators confined to 4 pole category are
processed by Global Vacuum Pressure Impregnation

K.K.Roy
Deputy General Manager,BHEL,Hyderabad
Email: kkroy@bhelhyd.co.in
(GVPI) technology to achieve superior dielectric
characteristics. However, single turn transposed half
bars are widely accepted design for higher capacity
machines. A novel design for higher MVA generator
has been developed with multi turn technology for
stator windings to achieve higher productivity. It is a
cost effective option due to the elimination of brazing
process of half bars and discontinuous insulation of
joints

2. Design development :
Demand for higher rating power generation
equipments in 4 pole category by the sugar, cement
and other process industry sectors is in increased trend
for the past several years. Cost effective designs and
higher productivity machines with high reliability to
meet the competition and survive in the market
necessitated to adopt a new approach from the existing
philosophy of transposed single turn half coil of 2 pole
configuration.
Preliminary design with multi turn diamond pulled
coils for high voltage armature windings with GVPI
technology had been worked out. Pros and cons of
launching the product with new concept had been
weighed. Merits of the design with the prevailing
roebel bar design philosophy was discussed in depth.

3 . Slot fill :
Occupancy by the rectangular copper conductors
to meet the power density, self insulation of copper
conductors, turns insulation and ground wall dielectric
insulation of windings to support the elevated induced
electro motive force in service are considered in
finalizing the active dimensions of the equi-spaced,
circumferentially distributed slots on the inner
periphery of the laminated stator core. Slot bottom
semi conductive liners and top confirmable dielectric

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packers below solid insulation wedge are other

engaging parts of the slot as shown in the fig.1.

Bottom
coil

technology that features accuracy, time cycle

reduction and efficiency. Coil cross sections in various
zones, overhang pictures and looping diagrams are
made possible at a click of single button on computer
with this soft skills.

6 . End winding restraining mechanism:

Sudden short forces in fault conditions during
operation will affect the end windings in multi
direction. MATLAB software program was developed
to calculate the sudden short circuit electro dynamic
forces as shown in the fig.2.

Top coil

SHORT CIRCUIT CURRENT OF U PHASE

25
i total
20

i udc
15

Figure 1. Slot fill

10

Nominal turns voltage worked out to be in the range of

200 to 250 volts. Dielectric insulation thickness was
considered to meet long endurance against continuous
induced higher turn voltage and also transient over
voltage stresses in operation.
The dielectric insulation consists of material
highly resistant to electrical discharges, such as mica
in fine paper supported by mechanically strengthened
glass backed woven cloth in tape form. In multi turn
coils, the mica paper taped insulation of copper
conductor serves as not only self insulation but also
turn insulation of the coils. Ground wall insulation
thickness is maintained as applicable for high voltage
windings and slot balance was worked out with
sufficient working clearance.
.4.
Vendor
conductors :

development

for

taped

Discussions were held with vendors on technoeconomic aspects and supply of mica glass insulated
rectangular copper conductors of specific size.
Vendors work places were visited to assess the
capabilities. Initially, small quantity sufficient for trial
coil looping and forming to diamond shape was
ordered. Taped conductors were processed and tested
at vendor works to ensure quality.

5 . Design automation :
A software program for product engineering to design
2D orthogonal drawing that combines calculations of
slot fill, over hang throw, setting parameters for
looping and coil spreader has been developed. It
contributed to the successful development of design

-5

i uac

-10

-15

0.01

.
Figure 2.
windings

0.02

0.03

0.04

0.05
TIME (Sec)

0.06

0.07

0.08

0.09

0.1

Sudden short circuit forces on end

If not supported mechanically, the over hang damages

are irreparable. The conical basket was held in radial
direction by epoxy glass laminates in turn bolted to the
welded on angular brackets .Dielectric insulation
epoxy bandage rings were positioned with confirmable
packers to restrain the outward deflection.
Intermediate soft confirmable spacers are introduced
in between over hang gaps to safeguard the winding
movement in tangential direction due to sudden short
circuit forces.
.

7. Sample
experience:

coil

manufacture

and

Looping and coil forming machine is used to produce

stator coils. Care was taken to avoid strip slipping
while looping. Wooden dummy stator was made to
check each coil for cross sectional size , pitch and
overhang profile.
Initially, a set of trial coils were manufactured,
checked for dimensions, assembled in the dummy
stator to confirm shape and pitch, tested for inter turn

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and high voltage. Coil was impregnated under GVPI

process by simulating the core configuration.

U test = 2.U N + 1000V

is the rated line to line voltage and U test

High voltage test at

where

UN

is the test voltage and the test period is 1 minute was

conducted.
The impulse wave strength of several
kilovolts/turn was used for inter turn insulation test.
The impulse voltage is adjusted to have a rise time of
1.2 s and a duration of 50 s . To ensure long term
reliability, tan delta, measurements were conducted.
Slope of the tan vs voltage curve is considered as
indirect indicator of the partial discharge level. Break
down strength of the insulation had been tested by
conducting high voltage test and found in the range of
60 to 65KV which is acceptable norm for mica epoxy
insulation high voltage bars of 11KV voltage levels.

system. The impregnated stator was tested for AC 50

Hz HV at two times the rated voltage plus 1 KV. Also
tan delta measurement and PD measurements were
carried out. The stator and rotor were assembled and
type tested for OCC, SCC, heat run, sudden short
circuit etc.

10 . Results of type tests :

The temperature rise of the windings is well
within the stipulated values. Breakdown strength of
insulation system is on par with the established
parameters. Tan delta results are well below the
specified values depicting smooth raising curve up to
120% of nominal voltage of the machine(Fig.3).
Tan delta of the insulation system
4
3.5

REF.VALUE

8 . Main coils manufacture :

After establishing the process, main coils
production was started. Dielectric insulation
strengthening at eye zones and additional fillers in
between turns in over hangs are inserted. The diamond
pulled coils were tested for any inter turn shorts using
impulse voltage testing method. Coils were insulated
with resin poor insulation with suitable thickness for
high voltage application. All coils were individually
tested for high voltage test before starting of winding.
Split turn was exclusively insulated and tied to the
remaining bunch of turns with accelerated soaked
synthetic fiber tapes to avoid physical strain during
assembly of stator winding.

9 . Assembly of coils :
Winding was carried out with the finished stator
core positioned on a rotating fixture for ease of
winding. Coils were inserted in slots, wedged and
tested. Overhang support system as per the developed
design was carried out. Connection between coil to
coil was done with strip to strip brazing of conductors
and insulated with insulation tapes. Phase ends were
taken out from connecting rings. Uniform air gaps
between phase separation coils around the periphery of
over hangs are ensured to avoid electric discharges and
weakening of dielectric strength of insulation during
load conditions.

Tan delta(%)

3
2.5
2

EXISTING M/C

1.5
1
0.5

HIGHER MVA M/C

0
0

10

12

KV

Figure 3. Tan delta comparison

11 . Merits over Roebel bar winding :

Development of multi turn coil technology for
higher capacity machines is well accepted due to the
overall cost advantage and reliability. Benefits over
roebel bar transposed half bars are as given below.
Each strip transposition bending is eliminated
Consolidation of over hang zone is not
required
Number of bars are halved
Brazing of strips and joints insulation is
avoided
Manufacture cycle time is reduced
Stage inspection for dielectric healthiness is
minimized
Material consumption is less

The completed stator was vacuum and pressure

impregnated (GVPI) in a resin tank and further cured
in a furnace to ensure a complete monolithic insulation

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12. Conclusion :
The proto type design and manufacture of higher
MVA, 4 pole generator was the result of well planned
and dedicated effort of the technologists
The challenge was the design of suitable turn
insulation system. The coil sizes and lengths were
carefully selected, so that a higher current carrying
capacity can be obtained within the frame size.
Proactive engineering inputs like selection of
insulation levels for turn induced voltages, necessary
slack in slot balance, end winding support mechanism,
sample coil evaluation and an error free design
through software automation ensured quality of
engineering inputs. This has ensured introduction of
the highest capacity 4 pole cylindrical pole multi turn
design VPI impregnated generators in India . Business
growth has been attained by capturing quite a number
of machines in this range through this design
development.
Further higher capacity generators with multi turn
coils for stator windings are planned for design
development. This is expected to be introduced in the
market by 2010.

13. Acknowledgment:
The authors would like to thank Bharat Heavy
Electricals Limited for giving permission to publish
the paper.
_____________________

References:
[1] W.Ladstaetter ,Dr.P.Marek, W.Grubelnik, F.Senn New
insulation technology impacts generator design,
Development HV Insulation Competence center Werndorf
8402 Werndorf,Austria
[2] Akinobu Nakayama,Kohji Haga,Seiichi Inoue
Development of global vacuum pressure impregnation
insulation system for turbogenerators
[3] Rudolf Btuetsch,John A.Allison,Ron scollay and Franz
Wolf vonroll isola,Switzerland, New trends in the
insulation technology of rotating high voltage machines
[4] Insulation of rotating machines

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