1

MANUFACTURING AND DESIGN OF

INSULATION SYSTEM FOR
AIR COOLED TURBO GENERATOR
BY V.P.I PROCESS

A PROJECT REPORT SUBMITTED IN PARTIAL

FULFILLMENT OF THE REQUIREMENTS
FOR THE AWARD OF

BACHELOR DEGREE
IN
ELECTRICAL ENGINEERING

SUBMITTED BY

G.VENKATESH BABU
(04A21A0258)
M.K.CHAITANYA SARMA
(04A21A0216)
M.V.SATYA TEJA
(04A21A0254)
L.PRANEETH CHAITANYA
(03A21A0226)

UNDER THE ESTEEMED GUIDANCE OF

T.Ravi. M.E.., R.K.MANOHAR

Asst prof. Sr DGM
Swarnandhra College Quality Control(E.M)
Narsapuram BHEL, Ramachandra puram
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CERTIFICATE

This is to certify that the project entitled “MANUFACTURING AND

DESIGN OF INSULATION SYSTEM FOR AIR COOLED TURBO
GENERATOR BY V.P.I PROCESS”
Submitted by
G.VENKATESH BABU (04A21A0258)
M.KRISHNA CHAITANYA SARMA (04A21A0216)
M.V.SATYA TEJA (04A21A0254)
L.PRANEETH CHAITANYA (03A21A0226)

In partial fulfillment of “BACHELORS DEGREE IN ELECTRICAL AND

ELECTRONICS ENGINEERING” for the academic Year 2007-2008 of IV-Year
from SWARNANDHRA COLLEGE OF ENGINEERING AND TECHNOLOGY,
affiliated to JNT UNIVERSITY, WEST GODAVARI DIST., A.P, INDIA.
A record of bonafide work carried by them under my guidance in “BHEL,
RAMACHANDRAPURAM, HYDERABAD-32”.

SIGNATURE OF PROJECT GUIDE

SHRI R.K.MANOHAR
DGM,B.Tech(Elect),(SQC&OR)
Electrical Machines,(Quality Control),
BHEL,Ramachandrapuram.
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ABSTRACT
In developing countries like India, power generation is a major break through to meet
the present demands of the nation. Power generation of several types are on forefront, the dominant
component of power generation is TURBO-GENERATOR which produces large capacity, the word
“TURBO” stands for turbine drive. Generally the turbines used to drive these turbo-generators are of
reaction type.
In large-scale industries manufacturing generators, insulation design plays a vital role.
Insulation is known to be the heart of the generator. If insulation fails, generator fails which leads to
the loss of crores of rupees. The latest technology for insulation in the world and adopted by BHEL,
(Hyderabad) unit is “VACUUM PRESSURE IMPREGNATION “which is of resin poor
thermosetting type. This type is preferred as it is highly reliable and possesses good mechanical,
thermal properties and di-electric strength. As the quantity of resin used is less, hence the over all cost
of insulation is reduced.
In our project we have made a detailed study of the VPI system of insulation. This
system is employed by BHEL first in the country and second in the world next to Germany.

Project Associates:
G.Venkatesh Babu (04A21A0258)
M.K.Chaitanya Sarma (04A21A0216)
M.V.Satya Teja (04A21A0254)
L.Praneeth Chaitanya (03A21A0226)

Project Guide External: Project Guide Internal:

Mr. R.K.Manohar., Sr.D.G.M, Mr. T.Ravi. M.E..,

Quality Control (E.M), Assistant prof.- EEE dept.
B.H.E.L. R.C.Puram. Swarnandhra College of
Engg and technology

APPROVED BY HOD OF EEE

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TABLE OF CONTENTS
1. ABSTRACT 3
1.1 ACKNOWLEDGEMENTS 10
1.2. PROFILE OF BHEL 11
1.3. PREFACE 13
2. INTRODUCTION 14
2.1 DRAWBACKS OF EARLY VPI PROCESS 14
2.2 ADVANTAGE OF PRESENT RESIN POOR VPI PROCESS 15
3. INTRODUCTION TO VARIOUS PARTS OF A GENERATOR 17
3.1 STATOR 17
3.2 ROTOR 18
3.3 FIELD CONNECTIONS AND MULTI CONTACTS 19
3.4 EXCITATION SYSTEM 19
3.5 PERMANENT MAGNET GENERATOR AND AVR 20
3.6 VARIOUS LOSSES IN A GENERATOR 23
4. MANUFACTURE OF GENERATOR 26
VARIOUS STAGES IN MANUFACTURE OF GENERATOR 26
4.1 STATOR MANUFACTURING PROCESS 27
4.1.1 STATOR CORE CONSTRUCTION 27
4.1.2 PREPARATION OF STATOR LAMINATIONS 27
4.1.3 RECEPTION OF SILICON STEEL ROLLS 27
4.1.4 SHEARING 27
4.1.5 BLANKING AND NOTCHING 27
4.1.6 COMPOUND NOTCHING 27
4.1.7 INDIVIDUAL NOTCHING 28
4.1.8 DEBURRING 28
4.1.9 VARNISHING 28
5. STATOR CORE ASSEMBLY 29
5.1 TRAIL PACKET ASSEMBLY 29
5.2 NORMAL CORE ASSEMBLY 29
5.2.1 STEPPED PACKET
ASSEMBLY 29
5.2.2 NORMAL PACKET
ASSEMBLY 29
5.2.2.1 IN PROCESS PRESSING
30
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5.2.2.2 FITTING OF CLAMPING

BOLTS 30
6. STATOR WINDING 30
6.1 CONDUCTOR MATERIAL USED IN COIL MANUFACTURING 31
6.2 TYPES OF CONDUCTOR COILS 31
7. ELECTRICAL INSULATION 32
7.1 STATOR WINDING INSULATION SYSTEM FEATURES 35
7.1.1 STRAND INSULATION 35
7.1.2 TURN INSULATION 39
7.1.3 GROUND WALL INSULATION 40
7.1.4 SLOT DISCHARGES 41
7.2 INSULATING MATERIALS 41
7.2.1 CLASSIFICATION OF INSULATING MATERIALS 42
7.2.2 INSULATING MATERIALS FOR ELECTRICAL MACHINES 42
7.3 ELECTRICAL PROPERTIES OF INSULATION AND FEW DEFINITIONS 44
7.3.1 INSULATION RESISTANCE 44
7.3.2 DIELECTRIC STRENGTH 44
7.3.3 POWER FACTOR 44
7.3.4 DIELECTRIC CONSTANT 44
7.3.5 DIELECTRIC LOSS 44
8 RESIN IMPREGNATION 45
8.1 INSULATION MATERIALS FOR LAMINATIONS 46
8.2 VARNISH 47
8.3 RESIN POOR SYSTEM
8.4 RESIN RICH SYSTEM 48
9. MANUFACTURE OF STATOR COILS 48
9.1 FOR RESIN POOR PROCESS 48
9.1.1 RECEPTION OF COPPER CONDUCTORS 50
9.1.2 TRANSPOSITION 50
9.1.3 PUTTY OPERATION 50
9.1.4 STACK
CONSOLIDATION 51
9.1.5 BENDING 51
9.1.6 FINAL TAPING 51
9.2 FOR RESIN RICH PROCESS 52
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9.2.1 PUTTY WORK

52
9.2.2 FINAL TAPING 52
9.2.3 FINAL BAKING
53
10. AN OVERVIEW 54
10.1 ADVANTAGES OF RESIN POOR SYSTEM 54
10.2 DISADVANTAGES OF RESIN POOR SYSTEM 54
10.3 ADVANTAGES OF RESIN RICH SYSTEM 54
10.4 DISADVANTAGES OF RESIN RICH SYSTEM 54
11. ASSEMBLY OF STATOR 54
11.1 RECEPTION OF STATOR CORE 55
11.2 WINDING HOLDERS ASSEMBLY 55
11.3 STIFFENER ASSEMBLY 55
11.4 EYE FORMATION 55
11.5 CONNECTING RINGS ASSEMBLY 56
11.6 PHASE CONNECTORS 56
12. THE VPI PROCESS 56
12.1 INTRODUCTION TO VPI PROCESS 56
12.2 HISTORY 57
12.3 VPI PROCESS FOR RESIN POOR INSULATED JOBS 59
12.3.1 GENERAL 59
12.3.2 PREHEATING
59
12.3.3 VACUUM CYCLE
60
12.3.4 IMPREGNATION
61
12.3.5 POST CURING
62
12.3.6 ELECTRICAL TESTING 63
12.4 GLOBAL PROCESSING 63
12.5 RESIN MANAGEMENT 63
12.6 SPECIFIC INSTRUCTIONS 63
12.7 PRECAUTIONS 64
12.8 FEATURES AND BENEFITS 64
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13. FACILITIES AVAILABLE IN VPI PLANT BHEL 66

13.1 DATA COLLECTION OF SAMPLES 68
13.1.1 INDO-BHARAT –II ROTOR 68
13.1.2 INDO BHARAT –II STATOR 70
13.1.3 HIGH VOLTAGE LEVELS OF STATOR/ROTOR WINDINGS FOR MULTI-
TURN MACHINES 74
13.1.4 TESTING RESULTS OF INDO BHARAT-II ROTOR 75
13.1.5 TESTING RESULTS OF INDO BHARAT-II STATOR 75
14. COMPARISON BETWEEN RESIN POOR AND RESIN RICH SYSTEMS 77
14.1 DRAWBACKS 78
14.2 SUGGESTIONS 78
14.3 JUSTIFICATION 78
15. PRESENT INSULATION SYSTEMS USED IN THE WORLD 83
15.1 WESTINGHOUSE ELECTRIC CO: THERMALASTIC™ 84
15.2 GENERAL ELECTRIC CO: MICAPALS I AND II™, EPOXY MICA MAT™,
MICAPAL HT™ AND HYDROMAT™ 85
15.3 ALSTHOM, GEC ALSTHOM, ALSTOM POWER: ISOTENAX™, RESITHERM™,
RESIFLEX™, RESIVAC™ AND DURITENAX™ 85
15.4 SIEMENS AG, KWU: MICALASTIC 86
15.5 ABB INDUSTRIE AG: MICADUR™, MICADUR COMPACT™,
MICAPACT™ AND MICAREX™ 86
15.6 TOSHIBA CORPORATION: TOSRICH™ AND TOSTIGHT-I™ 87
15.7 MISTUBISHI ELECTRIC CORPORATION 87
15.8 HITACHI LTD: HI-RESIN™ AND SUPER HIGH-RESIN 87
15.9 SUMMARY OF PRESENT DAY INSULATION 87
16. A NEW TREND IN INSULATION SYSTEM 88
16.1 MICALASTIC 88
16.2 MICALASTIC INSULATION IN ITAIPU’ 89
17. CONCLUSION 91
18. BIBLIOGRAPHY 92
A. LIST OF TABLES
A.1 CLASSIFICATION OF INSULATIONS ACCORDING TO TEMPERATURE
A.2 INSULATING MATERIALS FOR ELECTRICAL MACHINES
A.3 PROPERTIES OF AN ELECTRICAL INSULATION
A.4 MATERIALS USED IN RESIN POOR PROCESS
A.5 MATERIALS USED IN RESIN RICH PROCESS
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A.6 TABLE SHOWING TEMPERATURE AND TIME TO BE MAINTAINED FOR

DIFFERENT TYPE OF JOBS IN VPI
A.7 PREHEATING OF INDO BHARAT II ROTOR
A.8 IMPREGNATION OF INDO BHARAT II ROTOR
A.9 VACUUM CYCLE OF INDO BHARAT II ROTOR
A.10 PREHEATING OF INDO BHARAT II STATOR
A.11 VACUUM CYCLE OF INDO BHARAT II STATOR
A.12 POST CURING OF INDO BHARAT II STATOR
A.13 HIGH VOLTAGE LEVELS OF STATOR/ROTOR WINDINGS FOR MULTI TURN MACHINES
A.14 COMPARISON BETWEEN RESIN RICH AND RESIN POOR PROCESS
A.15 TAN Δ VALUES OF THE DIFFERENT PHASES OF A GENERATOR
A.16 TABULAR FORM FOR SHORT CIRCUIT CURRENTS AND VOLTAGES
A.17 TABULAR FORM SHOWING OPEN CIRCUIT VOLTAGES AND CURRENTS
OBTAINED IN THE TESTING

LIST OF FIGURES
B1 PHOTOGRAPH OF A SMALL ROUND ROTOR
B2 FIGURE SHOWING THE FLOW OF EDDY CURRENTS IN ROTOR BODY WITH AND WITHOUT LAMINATIONS
B3 FLOW DIAGRAM SHOWING VARIOUS STAGES IN GENERATOR MANUFACTURE
B4 FIG SHOWING THE SHAPE OF LAMINATIONS AFTER COMPLETION OF NOTCHING AND DEBURRING OPERATION
ROEBEL AND DIAMOND PULLED COILS
B5 SCHEMATIC DIAGRAM FOR A 3-Ф Y CONNECTED STATOR WINDING WITH 2 PARALLEL CONDUCTORS PER PHASE
B6 PHOTOGRAPHS OF END WINDINGS AND SLOTS OF RANDOM WOUND STATOR (COURTESY TECO WESTING HOUSE)
B7 PHOTOGRAPH OF A FORM WOUND STATOR WINDING (COURTESY TECO WESTING HOUSE)
B8 A SINGLE FORM WOUND COIL BEING INSERTED INTO TWO SLOTS
B9 C.S OF A RANDOM STATOR WINDING SLOT
B10 C.S OF A FORM WOUND MULTI-TURN SLOTS CONTAINING FORM WOUND MULTI-
TURN COILS.

B11 C.S OF A FORM WOUND MULTI-TURN SLOTS DIRECTLY COOLED ROEBEL BARS
B12 C.S OF MULTI-TURN COIL, WHERE THE TURN INSULATION AND STRAND INSULATION
ARE SAME

B13 SIDE VIEW SHOWING ONE WAY OF TRANSPOSING INSULATED STRANDS IN STATOR
BAR.

B14 C.S OF MULTI-TURN COIL WITH 3 TURNS AND 3 STRANDS PER TURN
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B15 LAYOUT OF MOULD USED IN BAKING OF STATOR BY RESIN RICH PROCESS

B16 VERTICAL VPI TANK FOR SMALLER JOBS
B17 RESIN TANK IN WHICH RESIN IS STORED
B18 MODERN STATOR BAR TAPING MACHINE THAT APPLIES THE TAPE ON BOTH IN THE
BOTH SIDES
B19 ROTOR OF THE WORLDS LARGEST HYDRO GENERATOR ITAIPU AT THE ASSEMBLY
LIST OF SYMBOLS ABBREVATIONS AND NOMENCLATURE
C.S. CROSS SECTION
AVR AUTOMATIC VOLTAGE REGULATOR
PMG PERMANENT MAGNETIC GENERATOR
VPI VACUUM PRESSURIZED IMPREGNATION
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1.1 ACKNOWLEDGEMENTS
The successful completion of any task would be incomplete without greeting those who made it
possible and whose guidance and encouragement made our effort success.
With profound gratitude, respect and pride, we express our sincere thanks to Sri.
Ramesh Babu, Secretary and correspondent of our college for providing necessary facilities for
doing the project.
We wish to express our gratitude to Dr. M. Muralidhara rao, our principal, for
having given us permission to carry out the project.
We express our deep sense of gratitude to Sri. P.V.V. Satya Narayana, Head of Dept.
of Electrical Engineering for his learned suggestions and encouragement which made this project a
success. We express sincere thanks to our internal guide Mr. T. Ravi, Asst prof, Department of
Electrical and Electronics Engineering for his encouragement, which made this project a success.
We express our earnest thanks to Mr. R. K. Manohar our external project guide who
had given valuable suggestions throughout our project. Finally we thank every one who directly or
indirectly helped for our project.
-Project Associates.
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1.2 PROFILE OF B.H.E.L.

Bharat Heavy Electrical Limited (BHEL) is today the largest engineering enterprise of India
with an excellent track record of performance. Its first plant was set up at Bhopal in 1956 under
technical collaboration with M/s. AEI, UK followed by three more major plants at Haridwar,
Hyderabad and Tiruchirapalli with Russian and Czechoslovak assistance.
These plants have been at the core of BHEL’s efforts to grow and diversify and become
India’s leading engineering company. The company now has 14 manufacturing divisions, 8 service
centers and 4 power sector regional centers, besides project sites spread all over India and abroad and
also regional operations divisions in various state capitals in India for providing quick service to
customers.
BHEL manufactures over 180 products and meets the needs of core-sectors like power,
industry, transmission, transportation (including railways), defense, telecommunications, oil business,
etc. Products of BHEL make have established an enviable reputation for high quality and reliability.
BHEL has installed equipment for over 62,000 MW of power generation-for Utilities, Captive
and Industrial users. Supplied 2,00,000 MVA transformer capacity and sustained equipment operating
in Transmission & Distribution network up to 400kV – AC & DC, Supplied over 25,000 Motors with
Drive Control System Power projects. Petrochemicals, Refineries, Steel, Aluminium, Fertiliser,
Cement plants etc., supplied Traction electric and AC/DC Locos to power over 12,000 Km Railway
network.
Supplied over one million Valves to Power Plants and other Industries. This is due to the
emphasis placed all along on designing, engineering and manufacturing to international standards by
acquiring and assimilating some of the best technologies in the world from leading companies in
USA, Europe and Japan, together with technologies from its-own R & D centers BHEL has acquired
ISO 9000 certification for its operations and has also adopted the concepts of Total Quality
Management (TQM).
BHEL presently has manufactured Turbo-Generators of ratings up to 560 MW and is in the
process of going up to 660 MW. It has also the capability to take up the manufacture of ratings unto
1000 MW suitable for thermal power generation, gas based and combined cycle power generation as-
well-as for diverse industrial applications like Paper, Sugar, Cement, Petrochemical, Fertilizers,
Rayon Industries, etc. Based on proven designs and know-how backed by over three decades of
experience and accreditation of ISO 9001. The Turbo-generator is a product of high-class
workmanship and quality. Adherence to stringent quality-checks at each stage has helped BHEL to
secure prestigious global orders in the recent past from Malaysia, Malta, Cyprus, Oman, Iraq,
Bangladesh, Sri Lanka and Saudi Arabia. The successful completion of the various export projects in
a record time is a testimony of BHEL’s performance.
 12

Established in the late 50’s, Bharat Heavy Electrical Limited (BHEL) is, today, a name to
reckon with in the industrial world. It is the largest engineering and manufacturing enterprises of its
kind in India and is one of the leading international companies in the power field. BHEL offers over
180 products and provides systems and services to meet the needs of core sections like: power,
transmission, industry, transportation, oil & gas, non-conventional energy sources and
telecommunication. A wide-spread network of 14 manufacturing divisions, 8 service centers and 4
regional offices besides a large number of project sites spread all over India and abroad, enables
BHEL to be close to its customers and cater to their specialized needs with total solutions-efficiently
and economically. An ISO 9000 certification has given the company international recognition for its
commitment towards quality. With an export presence in more than 50 countries BHEL is truely
India’s industrial ambassador to the world.
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1.3 PREFACE

Power is the basic necessity for economic development of a country. The production
of electrical energy and its per capital consumption is deemed as an index of standard of living in a
nation in the present day civilization. Development of heavy or large-scale industries, as well as
medium scale industries, agriculture, transportation etc, totally depend on electrical power resources
of engineers and scientists to find out ways and means to supply required power at cheapest rate. The
per capital consumption on average in the world is around 1200KWH, the figure is very low for our
country and we have to still go ahead in power generation to provide a decent standard of living for
people.
An AC generator is a device, which converts mechanical energy to electrical
energy. The alternator as it is commonly called works on the principle of ‘Electro Magnetic
Induction’. Turbo generators are machines which can generate high voltages and capable of
delivering KA of currents .so the designer should be cautious in designing the winding insulation. So
insulation design plays a major role on the life of the Turbo Generator. In our project we deal with the
“Manufacture process of turbo generator and its insulation design by VPI process.”
The first half of project is concerned with the aspects of generator manufacturing
comprising of stator manufacturing, in a step by step procedure involving different stages, and the
latter stage includes the insulation design of the generator by VPI process in a detailed manner, which
completes the generator design.
We more over stress mainly on VPI insulation process. Before going deep into the
topic we will start with a brief introduction and we conclude with the recent trends in the insulation
systems used all over the world.
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2. INTRDUCTION
Electrical insulating materials are defined as materials that offer a large resistance to
the flow of current and for that reason they are used to keep the current in its proper path i.e. along
the conductor. Insulation is the heart of the generator. Since generator principle is based on the
induction of e.m.f in a conductor when placed in a varying magnetic field. There should be proper
insulation between the magnetic field and the conductors. For smaller capacities of few KW, the
insulation may not affect more on the performance of the generator but for larger capacities of few
MW (>100MW) the optimization of insulation is an inevitable task, moreover the thickness of
insulation should be on par with the level of the voltage, also non homogenic insulation provisions
may lead to deterioration where it is thin and prone to hazardous short circuits, also the insulating
materials applied to the conductors are required to be flexible and have high specific (dielectric)
strength and ability to withstand unlimited cycles of heating and cooling.
Keeping this in view among other insulating materials like solids gases etc liquid
dielectrics are playing a major role in heavy electrical equipment where they can embedded deep into
the micro pores and provide better insulating properties. Where as solid di-electrics provide better
insulation with lower thickness and with greater mechanical strength. So the process of insulation
design which has the added advantage of both solid and liquid dielectrics would be a superior process
of insulation design. One such process which has all the above qualities is the VPI (vacuum
pressurised impregnation) process and has proven to be the best process till date.
2.1 Drawbacks of Early VPI Process:
DR. MEYER brought the VPI system with the collaboration of WESTING HOUSE in the
year 1956. It has been used for many years as a basic process for thorough filling of all interstices in
insulated components, especially high voltage stator coils and bars. Prior to development of
thermosetting resins, the widely used insulation system for 6.6kv and higher voltages was a VPI
system in which, Bitumen Bonded Mica Flake Tape is used as main ground insulation. The bitumen
is heated up to about 180°C to obtain low viscosity which aids thorough impregnation.
To assist penetration, the pressure in the autoclave was raised to 5 or 6 atmospheres. After
appropriate curing and calibration, the coils or bars were wound and connected up in the normal
manner. These systems performed satisfactorily in service provided they were used in their thermal
limitations.
In the late 1930’s and early 1940’s, however, many large units, principally turbine generators,
failed due to inherently weak thermoplastic nature of bitumen compound.
Failures were due to two types of problems:

a. Tape separation
 15

b. Excessive relaxation of the main ground insulation.

Much development work was carried out to try to produce new insulation systems, which
didn’t exhibit these weaknesses.
The first major new system to overcome these difficulties was basically a fundamental
Improvement to the classic Vacuum Pressure Impregnation process:
Coils and bars were insulated with dry mica flake tapes, lightly bonded with synthetic resin
and backed by a thin layer of fibrous material. After taping, the bars or coils were vacuum dried and
pressure impregnated in polyester resin. Subsequently, the resin was converted by chemical action
from a liquid to a solid compound by curing at an appropriate temperature, e.g. 150°C. this so called
thermosetting process enable coils and bars to be made which didn’t relax subsequently when
operating at full service temperature. By building in some permanently flexible tapings at the
evolutes of diamond shaped coils, it was practicable to wind them without difficulty. Thereafter,
normal slot packing, wedging, connecting up and bracing procedures were carried out. Many
manufacturers for producing their large coils and bars have used various versions of this Vacuum
Pressure Impregnation procedure for almost 30 years.
The main differences between systems have been used is in the type of micaceous tapes used
for main ground insulation and the composition of the impregnated resins. Although the first system
available was styrenated polyester, many developments have taken place during the last two decades.
Today, there are several different types of epoxy, epoxy-polyester and polyester resin in common use.
Choice of resin system and associated micaceous tape is a complex problem for the machine
manufacturer.
Although the classic Vacuum Pressure Impregnation technique has improved to a significant
extent, it is a modification to the basic process, which has brought about the greatest change in the
design and manufacture of medium-sized A.C industrial machines. This is the Global Impregnation
Process. Using this system, significant increases in reliability, reduction in manufacturing costs and
improved output can be achieved.

2.2 Advantage of present resin poor VPI process:

VPI is a process, which is a step above the conventional vacuum system. VPI includes
pressure in addition to vacuum, thus assuring good penetration of the varnish in the coil. The result is
improved mechanical strength and electrical properties. With the improved penetration, a void free
coil is achieved as well as giving greater mechanical strength. With the superior varnish distribution,
the temperature gradient is also reduced and therefore, there is a lower hot spot rise compared to the
average rise.
 16

In order to minimize the overall cost of the machine & to reduce the time cycle of the
insulation system vacuum pressure Impregnated System is used. The stator coils are taped with
porous resin poor mica tapes before inserting in the slots of cage stator, subsequently wounded stator
is subjected to VPI process, in which first the stator is vacuum dried and then impregnated in resin
bath under pressure of Nitrogen gas.
 17

3 Introduction to various parts of a Generator:

The manufacturing of a generator involves in manufacturing of all the parts of the
generator separately as per the design requirements and assembling them for the operation. It is worth
knowing the parts of the Turbo Generator. Usually for larger generators the assembling is done at the
generator installation area in order to avoid the damage due to mechanical stresses during
transportation, also this facilitates easy transportation. Let us have a view about various parts of a
turbo generator. Parts of a turbo generator:
1. Stator
2. Rotor
3. Excitation system
4. Cooling system
5. Insulation system
6. Bearings

3.1 STATOR:
3.1.1 STATOR FRAME
The stator frame is of welded steel single piece construction. It supports the laminated core
and winding. It has radial and axial ribs having adequate strength and rigidity to minimise core
vibrations and suitably designed to ensure efficient cooling. Guide bards are welded or bolted inside
the stator frame over which the core is assembled. Footings are provided to support the stator
foundation.

3.1.2 STATOR CORE

The stator core is made of silicon steel sheets with high permeability and low hysteresis and
eddy current losses. The sheets are suspended in the stator frame from insulated guide bars.
Stator laminations are coated with synthetic varnish; are stacked and held between sturdy steel
clamping plates with non-magnetic pressing fingers, which are fastened or welded to the stator frame.
In order to minimize eddy current losses of rotating magnetic flux which interacts with the
core, the entire core is built of thin laminations. Each lamination layer is made of individual
segments.
The segments are punched in one operation from electrical sheet steel lamination having high
silicon content and are carefully deburred. The stator laminations are assembled as separate cage
core without the stator frame. The segments are staggered from layer to layer so that a core of high
mechanical strength and uniform permeability to magnetic flux is obtained. On the outer
circumference the segments are stacked on insulated rectangular bars, which hold them in position.
 18

To obtain optimum compression and eliminate looseness during operation the laminations are
hydraulically compressed and heated during the stacking procedure. To remove the heat, spaced
segments are placed at intervals along the core length, which divide the core into sections to provide
wide radial passages for cooling air to flow.
The purpose of stator core is

1. To support the stator winding.

2. To carry the electromagnetic flux generated by rotor winding.
So selection of material for building up of core plays a vital role.

3.1.3 STATOR WINDING:

The stator winding is a fractional pitch two layer type, it consisting of individual bars.
The bars are located in slots of rectangular cross section which are uniformly distributed on the
circumference of the stator core.
In order to minimize losses, the bars are compared of separately insulated strands which
are exposed to 360.degrees transposing
To minimize the stator losses in the winding, the strands of the top and bottom bars are
separately brazed and insulated from each other.

3.2 ROTOR:
3.2.1 ROTOR SHAFT:
Rotor shaft is a single piece solid forging manufactured from a vacuum casting. Slots
for insertion of field winding are milled into the rotor body. The longitudinal slots are distributed over
the circumference. So that solids poles are obtained. To ensure that only high quality forgings are
used, strengthen test, material analysis and ultrasonic tests are performed during manufacture of the
rotor. After completion, the rotor is based in various planes at different speeds and then subjected to
an over speed test at 120% of rated speed for two minutes.

3.2.2. ROTOR WINDING AND RETAINING RINGS:

The rotor winding consisting of several coils, which are inserted into the slots and
series connected such that two coils groups from one pole. Each coil consists of several connected
turns, each of which consists of two half turns which are connected by brazing in the end section. The
individual turns of the coils are insulated against each other, the layer insulation L-shaped strips of
lamination epoxy glass fibre with nomax filler are used for slot insulation. The slot wedges are made
 19

of high electrical conductivity material and thus act as damper winding. At their ends the slots
wedges are short circuited through the rotor body.
The centrifugal forces of the rotor end winding are contained by single piece of non
magnetic high strengthen steel in order to reduce stray losses, each retaining rings with its shrinks
fitted insert ring is shrunk into the rotor body in an overhang position. The retaining rings are secured
in the axial position by a snap ring.
F igur
e 1:

Photograph of a small round rotor. The retaining rings are at the each end of the rotor.

3.3 FIELD CONNECTION AND MULTICONTACTS:

The field current is supplied to the rotor through multi contact system arranged at the
exciter side shaft end.

3.3.1 BEARINGS:
The generator rotor is supported in two sleeve bearings. To eliminate shaft current the
exciter and bearing is insulated from foundation plate and oil piping.
The temperature of each bearing is maintained with two RTD’s (Resistance Temperature
Detector) embedded in the lower bearing sleeve so that the ensuring point is located directly below
the Babbitt. All bearings have provisions for fitting vibration pick up to monitor shaft vibrations.
The oil supply of bearings is obtained from the turbine oil system.

3.4 EXCITATION SYSTEM:

In all industrial applications, the electrical power demand is ever increasing. This
automatically demands for the design, development and construction of increasingly large capacity
 20

Synchronous generators. These generators should be highly reliable in operation to meet the demand.
This calls for a reliable and sophisticated mode of excitation system.
When the first a.c generators were introducing a natural choice for the supply of field systems
was the DC exciter. DC exciter has the capability for equal voltage output of either polarity, which
helps in improving the generator transient performance. DC exciters, how ever, could not be adopted
for large ratings because of the problems in the design commutator and brush gear, which is
economically unattractive. Of –course, the problems are not uncommon in power stations but Of the
environment with sulphur vapours, acidic fumes as in the cases of petrochemical and fertilizer
industries, exposure of DC exciter. This adds to the problem of design.
Types of a.c exciters are:
(1) High frequency excitation
(2) Brush less excitation
(3) Static excitation
The high frequency D.C exciter is a specially designed “inductor type alternator” with no
winding on its rotor. It is designed to operate at high frequency to reduce the size of the rotor; the a.c
exciter was very reliable in operation. Though this system eliminates all problems associated with
commutator, it is not free from problems attributable to slip rings and its brush gear. Thus brushless
excitation system was introduced.
The BL exciter consists of field winding on the stator. This system proved to be highly reliable
and required less maintenance. Absence of power cables and external ac power supplies males the
system extremely reliable. The problem associated with brushes like fast wear out of brush, sparkling
etc, are eliminated.
This suffers from the disadvantage of lack of facility for field suppression in the case of an
internal fault in generator.
The system comprises shaft driven AC exciter with rotating diodes.

3.5 PERMANENT MAGNET GENERATOR AND AVR:

This system is highly reliable with least maintenance and is ideally suitable for gas driven
generators.
The static excitation system was developed contemporarily as an alternative to brush less
excitation system. This system was successfully adapted to medium and large capacity Turbo
generators. Though the system offers very good transient performance, the problems associated with
slip rings and brush gear system are still present.
 21

This system consists of rectifier transformer, thyristor converts, field breaker and AVR. This
system is ideally suitable where fast response is called for. The system is flexible in operation and
needs very little maintenance.
Thus, each excitation system has its own advantages and disadvantages. The selection of
system is influenced by the transient response required, nature of pollution and pollution level in the
power plant and cost of equipment.
Exciters are those components, which are used for giving high voltage to the generator during
the start up conditions. The main parts that are included in the exciter assembly are:
(1) Rectifier wheels
(2) Three phase main exciter
(3) Three phase pilot exciter
(4) Metering and supervisory equipment

3.5.1 RECTIFIER WHEELS:

The main components of the rectifier wheels are Silicon Diodes, which are arranged in the
rectifier wheels in a three-phase bridge circuit. The internal arrangement of diode is such that the
contact pressure is increased by centrifugal force during rotation.
There are some additional components contained in the rectified wheels. One diode each is
mounted in each light metal heat sink and then connected in parallel. For the suppression of
momentary voltage peaks arising from commutation, RC blocks are provided in each bridge in
parallel with one set of diodes. The rings from the positive shrunk on to the shaft. This makes the
circuit connections minimum and ensures accessibility of all the elements.

3.5.2 THREE PHASE PILOT EXCITER:

The three phase pilot exciter is a six-pole revolving field unit; the frame accommodates the
laminated core with the three-phase winding. The rotor consists of a hub with poles mounted on it.
Each pole consists of separate permanent magnets, which are housed, in non-metallic enclosures. The
magnets are placed between the hub and the external pole shoe with bolts. The rotor hub is shrunk on
to the free shaft end.

3.5.3 THREE PHASE MAIN EXCITER:

Three phases main exciter is a six-pole armature unit; the poles are arranged in the frame with
the field and damper winding. The field winding is arranged on laminated magnetic poles. At the pole
shoe, bars are provided which are connected to form a damper winding.
 22

The rotor consists of stacked laminations, which are compressed through bolts over
compression rings. The three- phase winding is inserted in the slots of the laminated rotor. The
winding conductors are transposed with in the core length and end turns of the rotor windings are
secure with the steel bands. The connections are made on the side facing of the rectifier wheels. After
full impregnation with the synthetic resin and curing, the complete rotor is shrunk on to the shaft.

3.5.4 AUTOMATIC VOLTAGE REGULATOR:

The general automatic voltage regulator is fast working solid thyristor controlled equipment.
It has two channels, one is auto channel and the other is manual. The auto channel is used for the
voltage regulation and manual channel is used for the current regulation. Each channel will have its
own firing for reliable operation.
The main features of AVR are:
(1) It has an automatic circuit to control outputs of auto channel and manual channel and
reduces disturbances at the generator terminals during transfer from auto regulation to
manual regulation.
(2) It is also having limiters for the stator current for the optimum utilization of lagging
and leading reactive capabilities of turbo generator.
(3)There will be automatic transfer from auto regulation to manual regulation in case do
measuring PT fuse failure or some internal faults in the auto channel.
(4)The generator voltage in both channels that is in the auto channel and the manual
channel can be controlled automatically.

3.5.5 COOLING SYSTEM:

Cooling is one of the basic requirements of any generator. The effective working of generator
considerably depends on the cooling system. The insulation used and cooling employed is inter-
related.
The losses in the generator dissipates as the heat, it raises the temperature of the generator. Due
to high temperature, the insulation will be affected greatly. So the heat developed should be cooled to
avoid excessive temperature raise. So the class of insulation used depends mainly on cooling system
installed.
There are various methods of cooling, they are:
a. Air cooling- 60MW
b. Hydrogen cooling-100MW
c. Water cooling –500MW
d. H 2 & Water cooling – 1000MW
Hydrogen cooling has the following advantages over Air-cooling:
 23

1. Hydrogen has 7 times more heat dissipating capacity.

2. Higher specific heat
3. Since Hydrogen is 1/14th of air weight. It has higher compressibility
4. It does not support combustion.
DISADVANTAGES:
1. It is an explosive when mixes with oxygen.
2. Cost of running is higher.
Higher capacity generators need better cooling system.

3.6 VARIOUS LOSSES IN A GENERATOR

In generators, as in most electrical devices, certain forces act to decrease the efficiency. These forces,
as they affect the generator, are considered as losses and may be defined as follows:
3.6.1 Copper loss in the winding.

3.6.2 Magnetic Losses.

3.6.3 Mechanical Losses

3.6.1 Copper loss:

The power lost in the form of heat in the armature winding of a generator is known as Copper
loss. Heat is generated any time current flows in a conductor.
I2R loss is the Copper loss, which increases as current increases. The amount of heat generated
is also proportional to the resistance of the conductor. The resistance of the conductor varies directly
with its length and inversely with its cross- sectional area. Copper loss is minimized in armature
windings by using large diameter wire. These includes rotor copper losses and Stator copper losses

3.6.2 Magnetic Losses (also known as iron or core losses)

(i) Hysteresis loss (Wh)
Hysteresis loss is a heat loss caused by the magnetic properties of the armature. When an
armature core is in a magnetic field the magnetic particles of the core tend to line up with the
magnetic field. When the armature core is rotating, its magnetic field keeps changing direction. The
continuous movement of the magnetic particles, as they try to align themselves with the magnetic
field, produces molecular friction. This, in turn, produces heat. This heat is transmitted to the
armature windings. The heat causes armature resistances to increase. To compensate for hysteresis
losses, heat-treated Silicon steel laminations are used in most dc generator armatures. After the steel
has been formed to the proper shape, the laminations are heated and allowed to cool. This annealing
process reduces the hysteresis loss to a low value.

(ii) Eddy Current Loss (We):

The core of a generator armature is made from soft iron, which is a conducting material with
desirable magnetic characteristics. Any conductor will have currents induced in it when it is rotated in
 24

a magnetic field. These currents that are induced in the generator armature core are called EDDY
CURRENTS. The power dissipated in the form of heat, as a result of the eddy currents, is considered
a loss.
Eddy currents, just like any other electrical currents, are affected by the resistance of the material in
which the currents flow. The resistance of any material is inversely proportional to its cross-sectional
area. Figure, view A, shows the eddy currents induced in an armature core that is a solid piece of soft
iron. Figure, view B, shows a soft iron core of the same size, but made up of several small pieces
insulated from each other. This process is called lamination. The currents in each piece of the
laminated core are considerably less than in the solid core because the resistance of the pieces is
much higher. (Resistance is inversely proportional to cross-sectional area.) The currents in the
individual pieces of the laminated core are so small that the sum of the individual currents is much
less than the total of eddy currents in the solid iron core.

B 1: Circuit showing flow of eddy currents in a rotor with and without laminations

As you can see, eddy current losses are kept low when the core material is made up of many thin
sheets of metal. Laminations in a small generator armature may be as thin as 1/64 inch. The
laminations are insulated from each other by a thin coat of lacquer or, in some instances, simply by
the oxidation of the surfaces. Oxidation is caused by contact with the air while the laminations are
being annealed. The insulation value need not be high because the voltages induced are very small.

Most generators use armatures with laminated cores to reduce eddy current losses.

These magnetic losses are practically constant for shunt and compound-wound generators, because in
their case, field current is constant.
3.6.3 Mechanical or Rotational Losses:
These consist of
(i) friction loss at bearings.
(ii) Air-friction or windage loss of rotating rotor armature.
These are about 10 to 20% of F.L losses.
Careful maintenance can be instrumental in keeping bearing friction to a minimum. Clean
bearings and proper lubrication are essential to the reduction of bearing friction. Brush friction is
 25

reduced by assuring proper brush seating, using proper brushes, and maintaining proper brush
tension.
Usually, magnetic and mechanical losses are collectively known as Stray Losses. These are also
known as rotational losses for obvious reasons.
As mentioned above, these losses are responsible for the rise in temperature of the generator
body hence an appropriate insulation should be used. Also the insulation should withstand the
generator voltage and currents. So an insulation whose breakdown voltage is of 5 to 6 times the
normal voltage is taken as Safety factor.
 26

4. MANUFACTURE OF GENERATOR

Various stages in generator manufacturing:

In our project we have a detail study of only stator, rotor and the insulation system
used for it. The parts excitation system, cooling system and bearings are external to the generator and
are treated as a completed one and are out of scope of our record. Now, generator manufacturing can
be broadly divided into three main parts:
1. Stator manufacture
2. Rotor manufacture
3. Exciter manufacture
The various stages involved in the generator manufacture and their sub processes are shown in
the flow diagram given below. This facilitates manufacture erection and transport of the stator.

B.3: flow diagram showing various stages involved in generator manufacture.

Now these sub processes are explained in detail below. Let us start with Stator.

4.1 STATOR MANUFACTURE PROCESS:

This stator manufacturing is a combination of two individual sub processes, namely
 Stator core construction and
 Coil construction and their assembly.
4.1.1 STATOR CORE CONSTRUCTION:
The stator core isn’t a solid iron type and is the assembly of strips of laminations. As the
reasons are explained in the Section 3.1 in the introduction to stator.
4.1.2 PREPARATION OF STATOR LAMINATIONS
As explained above, stator laminations are the important parts of the stator core and they
should be manufactured as per the design requirements and involves the following sub processes.
 27

4.1.3 RECEPTION OF SILICON STEEL ROLLS:

The silicon steel rolls received are checked for their physical, chemical, mechanical and
magnetic properties as per the specifications mentioned above.
In order to reduce the Hysterisis loss, silicon alloyed steel, which has low Hysterisis
constant is used for the manufacture of core. The composition of silicon steel is
Steel - 95.8 %
Silicon - 4.0 %
Impurities- 0.2 %
From the formula for eddy current loss it is seen that eddy current loss depends on the
thickness of the laminations. Hence to reduce the eddy current loss core is made up of thin
laminations which are insulated from each other. The thickness of the laminations is about 0.5
mm. The silicon steel sheets used are of COLD ROLLED NON-GRAIN ORIENTED
(CRANGO) type as it provides the distribution of flux throughout the laminated sheet.
4.1.4 SHEARING:
The cold rolled non grained oriented (CRNGO) steel sheets are cut to their outer
periphery to the required shapes by feeding the sheet into shearing press. For high rating
machines each lamination is build of 6 sectors (stampings), each of 60 cut according to the
specifications.
4.1.5 BLANKING AND NOTCHING:
Press tools are used in making the core bolt holes and other notches for the laminations.
Press tools are mainly of two types.
i. Compound notching tools.
ii. Individual notching tools.

4.1.6 COMPOUND OPERATION:

In this method the stamping with all the core bolt holes, guiding slots and winding
slots is manufactured in single operation known as Compound operation and the press tool
used is known as Compounding tool. Compounding tools are used for the machines rated
above 40 MW. Nearly 500 tons crank press is used for this purpose.
4.1.7 INDIVIDUAL OPERATIONS:
In case of smaller machines the stampings are manufactured in two operations. In the
first operation the core bolt holes and guiding slots are only made. This operation is known as
Blanking and the tools used are known as Blanking tools. In the second operation the
winding slots are punched using another tool known as Notching tool and the operation is
called Notching.
 28

4.1.8 DEBURRING OPERATION:

In this operation the burrs in the sheet due to punching are deburred. There are chances
of short circuit within the laminations if the burrs are not removed. The permissible is about 5
micrometer. For deburring punched sheets are passed under rollers to remove the sharp burs
of edges.

B4: Figure showing the shape of laminations after the completion of notching and
deburring operations.

4.1.9 VARNISHING:
Depending on the temperature withstand ability of the machine the laminations are
coated by varnish which acts as insulation. The lamination sheets are passed through
conveyor, which has an arrangement to sprinkle the varnish, and a coat of varnish is obtained.
The sheets are dried by a series of heaters at a temperature of around 260 – 350 oC. Two
coatings of varnish are provided in the above manner till 12-18 micrometer thickness of coat
is obtained. Here instead of pure varnish a mixture of Tin and Varnish is used such that the
mixture takes 44sec to empty a DIN4 CUP.

The prepared laminations are subjected to following tests.

 29

i) Xylol test - To measure the chemical resistance.

ii) Mandrel test - When wound around mandrel there should not be any cracks.
iii) Hardness test - Minimum 7H pencil hardness.
iv) IR value test - For 20 layers of laminations insulation resistance should not be less than
1MΩ.

5. STATOR CORE ASSEMBLY:

5.1 TRAIL PACKET ASSEMBLY:
Clamping plate is placed over the assembly pit; stumbling blocks are placed between the
clamping plates and the assembly pit. Clamping plate is made parallel to the ground by checking with
the spirit level. One packet comprising of 0.5 mm thickness silicon steel laminations is assembled
over the clamping plates by using mandrels and assembly pit .after assembling one packet thickness
of silicon laminations, inner diameter of the core is checked as per the drawing also the slot freeness
is checked with inspection drift .There should not be any projections inside or outside the slot. If all
the conditions are satisfied the normal core assembly is carried out by dismantling the trial packets.

5.2NORMAL CORE ASSEMBLY

5.2.1 Stepped packed assembly:
Stepped packets are assembled from the clamping plate isolating each packet with ventilation
laminations up to 4 to 5 packets of thickness 10cms for an air cooled turbo generator of 120MW.

5.2.2 Normal packet assembly:

Normal packet assembly is carried out using 0.5 mm silicon steel laminations up to
required thickness of 30mm by using mandrills and inspection drift after normal packet assembly
completion, one layer of HGL laminations are placed and one layer of ventilation lamination are
placed over them. Then again normal packet assembly is carried as above. The thickness of each
lamination is 0.5 mm and the thickness of lamination separating the packets is about 1 mm. The
lamination separating each packet has strips of nonmagnetic material that are welded to provide radial
ducts. The segments are staggered from layer to layer so that a core of high mechanical strength and
uniform permeability to magnetic flux is obtained. Stacking mandrels and bolts are inserted into the
windings slot bores during stacking provide smooth slot walls.
 30

5.2.2.1 In process pressings

To obtain the maximum compression and eliminate under setting during operation, the
laminations are hydraulically compressed and heated during the stacking procedure when certain
heights of stacks are reached.
The packets are assembled as above up to 800mm as above and 1 st pressing is carried
using hydraulic jacks up to 150kg/cm2 and the pressing is carried out for every 800mm and a pre final
pressing is done before the core length almost reach the actual core. Now the core is tested for the
design specifications and the compensation is done by adding or removing the packets.

5.2.2.2 Fitting of clamping bolts:

The complete stack is kept under pressure and locked in the frame by means of clamping
bolts and pressure plates. The clamping bolts running through the core are made of nonmagnetic steel
and are insulated from the core and the pressure plates to prevent them from short circuiting the
laminations and allowing the flow of eddy currents.
The pressure is transmitted from the clamping plates to the core by clamping fingers. The
clamping fingers extend up to the ends of the teeth thus, ensuring a firm compression in the area of
the teeth. The stepped arrangement of the laminations at the core ends provides an efficient support
to tooth portion and in addition contributes to the reduction of stray load losses and local heating in
that area due to end leakage flux.
The clamping fingers are also made of non-magnetic steel to avoid eddy-current losses. After
compression and clamping of core the rectangular core key bars are inserted into the slots provided in
the back of the core and welded to the pressure plates. All key bars, except one, are insulated from
the core to provide the grounding of the core.

WINDING
The next important consideration is winding. The stator winding and rotor winding consist of several
components, each with their own function. Furthermore, different types of machines have different
components. Stator windings are discussed separately below.

6. Stator Winding
There are three main components in a stator, they are
a. copper conductors (although aluminum is sometimes used).
b. The stator core.
c. Insulation.
6.1 Conducting material used in coil manufacturing:
Copper material is used to make the coils. This is because
i) Copper has high electrical conductivity with excellent mechanical properties
 31

ii) Immunity from oxidation and corrosion

iii) It is highly malleable and ductile metal.
6.2 TYPES OF CONDUCTOR COILS:
Basically there are three types of stator winding structures employed over the range from 1 KW to
1000 MW.
1. Random wound stators.
2. Form-wound stators using multi turn coils.
3. Form-wound stators using Roebel bars.
Out of these, two types of coils are manufactured and used in BHEL, Hyderabad.
1) Diamond pulled multi-turn coil (full coiled).
2) Roebel bar (half-coil).
In general, random-wound stators are typically used for machines less than several hundred
KW. Form-wound coil windings are used in most large motors and many generators rated up to 50 to
100 MVA. Roebel bar windings are used for large generators. Although each type of construction is
described below, some machine manufacturers have made hybrids that do not fit easily into any of the
above categories; these are not discussed in the project.
Generally in large capacity machines ROEBEL bars are used. These coils were constructed
after considering the skin effect losses. In the straight slot portion, the conductors or strips are
transposed by 360 degrees.
The transposition is done to ensure that all the strips occupy equal length under similar
conditions of the flux. The transposition provides for a mutual neutralization of the voltages induced
in the individual strips due to the slot cross field and ensures that no or only small circulating currents
exists in the bar interior. Transposition also reduced eddy current losses and helps in obtaining
uniform e.m.f. More about transposition is discussed later in the section with diagrammatic quote.
The copper is a conduit for the stator winding current. In a generator, the stator output current
is induced to flow in the copper conductors as a reaction to the rotating magnetic field from the rotor.
In a motor, a current is introduced into the stator, creating a rotating magnetic field that forces the
rotor to move. The copper conductors must have a cross section large enough to carry all the current
required without overheating.
 32

B5 schematic diagram for a three –phase Y-connected stator winding with two parallel
conductors per phase

The diagram shows that each phase has one or more parallel paths for current flow. Multiple
parallels are often necessary since a copper cross section large enough to carry the entire phase
current may result in an uneconomic stator slot size. Each parallel consists of a number of coils
connected in series. For most motors and small generators, each coil consists of a number of turns of
copper conductors formed into a loop. The rationale for selecting the number of parallels, the number
of coils in series, and the number of turns per coil in any particular machine is beyond the scope of
our project.
The stator core in a generator concentrates the magnetic field from the rotor on the copper
conductors in the coils. The stator core consists of thin sheets of magnetic steel (referred to as
laminations). The magnetic steel acts as a low-reluctance (low magnetic impedance) path for the
magnetic fields from the rotor to the stator, or vice versa for a motor. The steel core also prevents
most of the stator winding magnetic field from escaping the ends of the stator core, which would
cause currents to flow in adjacent conductive material.

7. Electrical Insulation:
The final major component of a stator winding is the electrical insulation. Unlike copper
conductors and magnetic steel, which are active components in making a motor or generator function
the insulation is passive. That is, it does not help to produce a magnetic field or guide its path.
Generator and motor designers would like nothing better than to eliminate the electrical insulation,
since the insulation increases machine size and cost, and reduces efficiency, without helping to create
any torque or current. Insulation is “overhead,” with a primary purpose of preventing short circuits
 33

between the conductors or to ground. However, without the insulation, copper conductors would
come in contact with one another or with the grounded stator core, causing the current to flow in
undesired paths and preventing the proper operation of the machine. In addition, indirectly cooled
machines require the insulation to be a thermal conductor, so that the copper conductors do not
overheat.
The insulation system must also hold the copper conductors tightly in place to prevent
movement. The stator winding insulation system contains organic materials as a primary constituent.
In general, organic materials soften at a much lower temperature and have a much lower mechanical
strength than copper or steel. Thus, the life of a stator winding is limited most often by the electrical
insulation rather than by the conductors or the steel core. Furthermore, stator winding maintenance
and testing almost always refers to testing and maintenance of the electrical insulation.

B6 Photographs of end windings and slots of random wound stator (Courtesy TECO Westing
house)
 34

B7 Photograph of a form wound stator winding (courtesy TECO Westing house)

High purity (99%) copper conductors/strips are used to make the coils. This results in high
strength properties at higher temperatures so that deformations due to the thermal stresses are
eliminated.

B8 A single form wound coil being inserted into two slots

 35

7.1 STATOR WINDING INSULATION SYSTEM FEATURES

The stator winding insulation system contains several different components and features which
together ensure that electrical shorts do not occur, that the heat from the conductor I2R losses are
transmitted to a heat sink, and that the conductors do not vibrate in spite of the magnetic forces.
The basic stator insulation system components are the:
1. Strand (or sub conductor) insulation
2. Turn insulation
3. Ground wall (or ground or earth) insulation
Figures 1.8 and 1.9 show cross sections of random-wound and form-wound coils in a stator slot,
and identify the above components. Note that the form-wound stator has two coils per slot; this is
typical.
Figure 1.10 is a photograph of the cross section of a multi-turn coil. In addition to the main
insulation components, the insulation system sometimes has high-voltage stress-relief coatings and
end-winding support components.
The following sections describe the purpose of each of these components. The mechanical, thermal,
electrical, and environmental stresses that the components are subjected to are also described.

7.1.1 Strand Insulation

In random-wound stators, the strand insulation can function as the turn insulation, although extra
sleeving is sometimes applied to boost the turn insulation strength in key areas. Many form-wound
machines employ separate strand and turn insulation. The following mainly addresses the strand
insulation in form-wound coils and bars. Strand insulation in random wound machines will be
discussed as turn insulation. Section 1.4.8 discusses strand insulation in its role as transposition
insulation.
There are both electrical and mechanical reasons for stranding a conductor in a form wound coil or
bar.
From a mechanical point of view, a conductor that is big enough to carry the current needed in the
coil or bar for a large machine will have a relatively large cross-sectional area. That is, a large
conductor cross section is needed to achieve the desired ampacity. Such a large conductor is difficult
to bend and form into the required coil/bar shape. A conductor formed from smaller strands (also
called sub-conductors) is easier to bend into the required shape than one large conductor.

B9 C.S of a random stator winding slot

 36

From an electrical point of view, there are reasons to make strands and insulate them from one
another. It is well known from electromagnetic theory that if a copper conductor has a large enough
cross-sectional area, the current will tend to flow on the periphery of the conductor. This is known as
the skin effect. The skin effect gives rise to a skin depth through which most of the current flows.
The skin depth of copper is 8.5 mm at 60 Hz. If the conductor has a cross section such that the
thickness is greater than 8.5 mm, there is a tendency for the current not to flow through the center of
the conductor, which implies that the current is not making use of all the available cross section. This
is reflected as an effective AC resistance that is higher than the DC resistance. The higher AC
resistance gives rise to a larger I2R loss than if the same cross section had been made from strands
that are insulated from one another to prevent the skin effect from occurring. That is, by making the
required cross section from strands that are insulated from one another, all the copper cross section is
used for current flow, the skin effect is negated, and the losses are reduced.
In addition, Eddy current losses occur in solid conductors of too large a cross section. In the slots, the
main magnetic field is primarily radial, that is, perpendicular to the axial direction. There is also a
small circumferential (slot leakage) flux that can induce eddy currents to flow. In the end-winding, an
axial magnetic field is caused by the abrupt end of the rotor and stator core. This axial magnetic field
can be substantial in synchronous machines that are under-excited.
By Ampere’s Law, or the ‘right hand rule’, this axial magnetic field will tend to cause a current to
circulate within the cross section of the conductor (Figure 1.11). The larger the cross sectional area,
the greater the magnetic flux that can be encircled by a path on the periphery of the conductor, and
the larger the induced current. The result is a greater I2R loss from this circulating current. By
reducing the size of the conductors, there is a reduction in stray magnetic field losses, improving
efficiency.
The electrical reasons for stranding require the strands to be insulated from one another. The voltage
across the strands is less than a few tens of volts; therefore, the strand insulation can be very thin. The
strand insulation is subject to damage during the coil manufacturing process, so it must have good
mechanical properties. Since the strand insulation is immediately adjacent to the copper conductors
that are carrying the main stator current, which produces the I2R loss, the strand insulation is exposed
to the highest temperatures in the stator. Therefore, the strand insulation must have good thermal
properties. Section 7.1.1 describes in detail the strand insulation materials that are in use. Although
manufacturers ensure that strand shorts are not present in a new coil, they may occur during service
due to thermal or mechanical aging. A few strand shorts in form-wound coils/bars will not cause
winding failure, but will increase the stator winding losses and cause local temperature increases due
to circulating currents.
 37

B10 C.S of a form wound multi-turn slots containing form wound multi-turn coils.

7.1.2 Turn Insulation

The purpose of the turn insulation in both random- and form-wound stators is to prevent shorts
between the turns in a coil. If a turn short occurs, the shorted turn will appear as the secondary
winding of an autotransformer. If, for example, the winding has 100 turns between the phase terminal
and neutral (the “primary winding”), and if a dead short appears across one turn (the “secondary”),
then 100 times normal current will flow in the shorted turn. This follows from the transformer law:
npIp = nsIs (1.1)
Where n refers to the number of turns in the primary or secondary, and I is the current in the
primary or secondary. Consequently, a huge circulating current will flow in the faulted turn, rapidly
 38

overheating it. Usually, this high current will be followed quickly by a ground fault due to melted
copper burning through any ground-wall insulation. Clearly, effective turn insulation is needed for
long stator winding life.
B11 C.S of a form wound multi-turn slots directly cooled roebel bars
The power frequency voltage across the turn insulation in a random-wound machine can
range up to the rated phase-to-phase voltage of the stator because, by
definition, the turns are randomly placed in the slot and thus may be
adjacent to a phase-end turn in another phase, although many motor
manufacturers may insert extra insulating barriers between coils in the
same slot but in different phases and between coils in different phases in
the end-windings. Since random winding is rarely used on machines rated
more than 600 V (phase-to-phase), the turn insulation can be fairly thin.
However, if a motor is subject to high-voltage pulses, especially from
modern inverter-fed drives (IFDs), inter-turn voltage stresses that far
exceed the normal maximum of 600 Vac can result. These high-voltage
pulses give rise to failure mechanisms, as discussed in Section 8.7.
The power frequency voltage across adjacent turns in a form-wound multi-turn coil is well defined.
Essentially, one can take the number of turns between the phase terminal and the neutral and divide it
into the phase–ground voltage to get the voltage across each turn. For example, if a motor is rated
4160 Vrms (phase–phase), the phase–ground voltage is 2400V.
This will result in about 24 Vrms across each turn, if there are 100 turns between the phase end and
neutral. This occurs because coil manufacturers take considerable trouble to ensure that the
inductance of each coil is the same, and that the inductance of each turn within a coil is the same.
Since the inductive impedance (XL) in ohms is:
XL = 2_fL (1.2)
Where f is the frequency of the AC voltage and L is the coil or turn inductance, the turns appear as
impedances in a voltage divider, where the coil series impedances are equal. In general, the voltage
across each turn will be between about 10 Vac (small form-wound motors) to 250 Vac (for large
generator multi turn coils).
The turn insulation in form-wound coils can be exposed to very high transient voltages associated
with motor starts, IFD operation, or lightning strikes. Such transient voltages may age or puncture the
turn insulation. This will be discussed in later sections. As described below, the turn insulation around
the periphery of the copper conductors is also exposed to the rated AC phase–ground stress, as well as
the turn–turn AC voltage and the phase coil-to-coil voltage.
Before about 1970, the strand and the turn insulation were separate components in multi turn coils.
Since that time, many stator manufacturers have combined the strand and turn insulation. Figure 1.12
 39

shows the strand insulation is upgraded (usually with more thickness) to serve as both the strand and
the turn insulation. This eliminates a manufacturing step (i.e., the turn taping process) and increases
the fraction of the slot cross section that can be filled with copper. However, some machine owners
have found that in-service failures occur sooner in stators without a separate turn insulation
component.
Both form-wound coils and random-wound stators are also exposed to mechanical and thermal
stresses. The highest mechanical stresses tend to occur in the coil forming process, which requires the
insulation-covered turns to be bent through large angles, which can stretch and crack the insulation.
Steady-state, magnetically induced mechanical vibration forces (at twice the power frequency) act on
the turns during normal machine operation. In addition, very large transient magnetic forces act on
the turns during motor starting or out-of-phase synchronization in generators. These are discussed in
detail in Chapter 8. The result is the turn insulation requires good mechanical strength.
The thermal stresses on the turn insulation are essentially the same as those described above for the
strand insulation. The turn insulation is adjacent to the copper conductors, which are hot from the I2R
losses in the winding. The higher the melting or decomposition temperature of the turn insulation, the
greater the design current that can flow through the stator.
In a Roebel bar winding, no turn insulation is used and there is only strand insulation. Thus, as will be
discussed in later sections, some failure mechanisms that can occur with multi turn coils will not
occur with Roebel bar stators.

7.1.3 Ground wall Insulation

Ground wall insulation is the component that separates the copper conductors from the
grounded stator core. Ground wall
insulation failure usually triggers a
ground fault relay, taking the motor or
generator off-line.* Thus the stator
ground wall insulation is critical to the
proper operation of a motor or
generator. For a long service life, the
ground wall must meet the rigors of the
electrical, thermal, and mechanical
stresses that it is subject to.

B12 C.S of multi-turn coil, where the turn insulation and strand insulation are same
 40

7.1.4 Slot Discharges:

Slot discharges occur if there are gaps within the slot between the surface of the insulation and
that of the core. This may cause ionization of the air in the gap, due to breakdown of the air at the
instances of voltage distribution between the copper conductor and the iron.
Within the slots, the outer surface of the conductor insulation is at earth potential, in the
overhanging it will approach more nearly to the potential of the enclosed copper. Surface discharge
will take place if the potential gradient at the transition from slot to overhang is excessive, and it is
usually necessary to introduce voltage grading by means of a semi-conducting (graphite) surface
layer, extending a short distance outward from the slot ends.
So insulation of these stator bars is an inevitable task. It is worth now to know about
insulation. As we told before insulation is the heart of the generator now let us move to the most
interesting and important topic insulation.

7.2 INSULATING MATERIALS:

Insulating materials or insulators are extremely diverse in origin and properties. They are
essentially non-metallic, are organic or inorganic, uniform or heterogeneous in composition, natural
or synthetic. Many of them are of natural origin as, for example, paper, cloth, paraffin wax and
natural resins. Wide use is made of many inorganic insulating materials such as glass, ceramics and
mica. Many of the insulating materials are man-made products and manufactured in the form of
resins, insulating films etc., in recent years wide use is made of new materials whose composition and
organic substances. These are the synthetic Organo-silicon compounds, generally termed as silicones.

Properties of a good Insulating Material:

The basic function of insulation is to provide insulation live wire to live wire or to the earth. A
good insulating material needs the following physical and electrical properties.
1. It should be good conductor to heat and bad conductor to electricity.
2. It should withstand the designed mechanical stress.
3. It should have good chemical and thermal resistively and environmental resistively.
4. High dielectric strength sustained at elevated temperatures.
5. High resistivity or specific resistance
6. Low dielectric Hysterisis.
7. Good thermal conductivity.
8. High degree of thermal stability i.e. it should not deteriorate at high temperatures.
9. Low dissipation factor.
10. Should be resistant to oils and liquid, gas flames, acids and alkalis.
11. Should be resistant to thermal and chemical deterioration.
 41

7.2.2 CLASSIFICATION OF INSULATING MATERIAL:

The insulating material can be classified in the following two ways.
I. Classification according to substance and materials.
II. Classification according to temperature.

a. Classification according to substance and materials:

1. Solids (Inorganic and organic)
EX: Mica, wood slate, glass, porcelain, rubber, cotton, silks, rayon, ethylene, paper and cellulose
materials etc.
2. Liquids (oils and varnishes)
EX: linseed oil, refined hydrocarbon minerals oils sprits and synthetic varnishes etc.
3. Gases
EX: Dry air, carbon dioxide, nitrogen etc.

A.1 CLASSIFICATION ACCORDING TO TEMPERATURE:

Class Permissible Materials
temperature
Y 90° Cotton, silk, paper, cellulose, wood etc neither impregnated
nor immersed in oil. These are unsuitable for electrical
machine and apparatus as they deteriorate rapidly and are
extremely hygroscopic.
A 105° Cotton, silk & paper, natural resins, cellulose esters,
laminated wool, varnished paper.
E 120° Synthetic material of cellulose base
B 130° Mica, asbestos, glass fibre with suitable bonding substance
F 155° Material of class B with binding material of higher thermal
stability.
H 180° Glass fibre and asbestos material and built up mica with
silicon resins.
C Above Mica, porcelain, quartz, glass (without any bonding agent)
180° with silicon resins of higher thermal stability.
 42

7.2.2 INSULATING MATERIALS FOR ELECTRICAL MACHINES:

Shelf life
Name of Insulation (In months) Application
Material Class At At
20 oC 5oc
1. Samicatherm calmica F 6 12 Main insulation of
glass-n, mimica, domica, stator bars
folium, filamic
novobond-s, epoxy
therm laxman isola
calmicaflex
2. Samica flex H 4 8 Overhang insulation of
motor coils, at 3rd
bends of multi turn coil
3. Vectro asbestos B/F 2 8 Main pole coils of
(365.02/365.32) synchronous machines
4. (used in resin rich)
Epoxide impregnated glass 6 12 Winding holders and
F
cloth inter-half insulation
5. Polyester resin mat & 6 Bar to winding holder
rope & stiffener groove of
support segment of
clamping plate
6. Glassoflex F 6 12 Inter-turn insulation of
Turbo laminate rotor winding
7. Hyper seal tape F 6 12 As finishing layer in
overhangs of motor
coils
8. SIB775 or 4302 varnish F 6 12 Stack Consolidation of
stator bars
9. SIB475 or 4301 varnish F 6 12 Base coat varnish
before taping of stator
bars
10. SIB 643 or8003 Varnish 4 8 Conductive coat in
or K8886 varnish straight portion of
stator bars
11. SIB 642 or 8001 varnish 4 8 At slot emerge portion
on stator bars
A.2 Insulating materials for electrical machines

7.3 FEW DEFINITIONS OF ELECTRIAL PROPERTIES OF INSULATION:

7.3.1 INSULATON RESISTANCE:
It may be defined as the resistance between two conductors usually separated by insulating
materials. It is the total resistance in respect of two parallel paths, one through the body and
other over the surface of the body.
Insulation Resistance is influenced by the following factors.

1) It falls with every increase in temperature.

 43

2) The sensitivity of the insulation is considerable in the presence of moisture.

3) Insulation resistance decrease with increase in applied voltage.

7.3.2 DIELECTRIC STRENGTH:

The voltage across the insulating material is increased slowly the way in which the leakage
current increases depend upon the nature and condition material.

7.3.3 POWER FACTOR:

Power factor is a measure of the power losses in the insulation and should be low. It varies
with the temperature of the insulation. A rapid increase indicates danger.

7.3.4 DIELECTRIC CONSTANT:

This property is defined as the ratio of the electric flux density in the material .To that
produced in free space by the same electric force.

7.3.5 DIELECTRIC LOSS:

The dielectric losses occur in all solid and liquid dielectric due to
(b) Conduction current
(c) Hysterisis.

Additional to the Electrical properties there are many factors such as thermal, chemical etc.., they are
tabulated as below.
S.No Thermal Properties Chemical Properties Mechanical Properties
1. Specific heat Resistance to external chemical Density
2. Thermal conductivity. effects. Viscosity
3. Thermal plasticity Resistance to chemical in soils. Moisture absorption
4. Ignitability Hardness of surface
5. Softening point Effect of moisture and water. Surface tension
6. Heat Aging Uniformity.
7. Thermal expansion.

A.3 properties of electrical insulation

 44

8. Resin Impregnation:
Resin impregnation fills the porosity of a part with a resin to create a pressure-tight part for
hydraulic applications which can withstand several thousand psi, to improve machine ability, or to
allow electroplating. The parts are placed in a mesh basket and loaded into a vacuum tank. This is
then submerged in a bath of Anaerobic resin. A vacuum is pulled to remove all air from the porosity
of the parts. This vacuum is released to and the tank is pressurised, causing the resin to be drawn into
the porosity of the parts. Parts that typically undergo resin impregnation include hydraulic fittings for
pressure tightness and plating, covers and plated for pressure tightness, as well as machined
components.
The previous method of sealing parts was a furnace treatment, which formed a hard oxide layer on
the internal and external surfaces of a part, filling the porosity. Most machining operations were
performed prior to sealing the part because the hard oxide layer adversely affected mach inability.
Residue left by traditional cutting fluids tended to inhibit the formation of an oxide layer. With resin
impregnation, conventional cutting fluids can be used because the furnace treatment is eliminated
resulting in improved mach inability. These fluids efficiently remove heat from the cutting tool,
extending the tool life. Machining a porous part effectively creates a continuous interrupted cut.
Each time the tool impacts metal after passing through a pore, it may chip and become dull. Resin
impregnation reduces that effect and may also provide added lubrication to the cutting tool. Before
resin impregnation, many parts were mechanically plated. Resin impregnation allows the use of
electroplating.
EPOXY RESINS:
Epoxy resins are poly ethers derived from Epi-Chloro Hydrin and Bis-Phenol
monomers through condensation polymerization process. These resins are product of alkaline
condensed of Epi-Chloro Hydrin and product of alkaline condensed of Epi-Chloro Hydrin and Poly-
Hydric compounds.
In Epoxy Resins cross-linking is produced by cure reactions. The liquid polymer has reactive
functional group like oil etc, otherwise vacuum as pre polymer. The pre polymer of epoxy resins
allowed to react curing agents of low inductor weights such as poly-amines, poly-amides, poly-
sulphides, phenol, urea, formaldehyde, acids anhydrides etc, to produce the three dimensional cross
linked structures.
Hence epoxy resins exhibit outstanding toughness, chemical inertness and excellent
mechanical and thermal shock resistance. They also possess good adhesion property. Epoxy resins
can be used continuously up to 300°F, but with special additions, the capability can be increased up to
a temperature of 500°F.
 45

Epoxy resins are made use as an efficient coating material. This includes coating of tanks
containing chemicals, coating for corrosion and abrasion resistant containers. Epoxy resins are made
up of as attractive corrosion and wear resistant floor ware finishes.

These are also used as industrial flooring material. They are also used as highways Surfacing
and patching material. Moulding compounds of epoxy resins such as pipe fitting electrical
components bobbins for coil winding and components of tooling industrial finds greater application
in industries.

The epoxy resins similar to polyester resins can be laminated and Fiber Reinforced (FPR) and
used in glass fiber boats, lightweight helicopters and aero planes parts.
In the modern electronic industry, the application of epoxy resins is great. Potting and
encapsulation (coating with plastic resin) is used for electronic parts. Most of the printed circuits
bodies are made of laminated epoxy resin which is light but strong and tough.

PROPERTIES:

1) Epoxy resins have good mechanical strength less shrinkage and excellent dimensional stable
after casting.

2) Chemical resistance is high.

3) Good adhesion to metals.

4) To impact hardness certain organic acid anhydrides and alphabetic amines are mixed.

APPLICATIONS:

1) They are used in the manufacture of laminated insulating boards.

2) Dimensional stability prevents crack formation in castings.
3) They are also used as insulating varnishes.
8.1 INSULATING MATERIAL FOR LAMINATIONS: -
The core stacks in modem machines are subjected to high pressers during assembly and there
fore to avoid metal-to-metal contact, laminations must be well insulated. The main requirements of
good lamination insulation are homogeneously in thin layers toughness and high receptivity.
We use varnish as insulating material for laminations.

8.2 VARNISH

This is most effective type of insulation now available. It makes the laminations nest proofs
and is not affected by the temperature produced in electrical machines varnish is usually applied to
both sides of lamination to a thickness of about 0.006mm. On plates of 0.35mm thickness varnish
 46

gives a stacking factor about 0.95.In order to achieve good insulation properties the following
processes are in BHEL.
• THERMOPLASTIC PROCESS OF INSULATION
• THERMOSETTING PROCESS OF INSULATION

BHEL is practicing only thermosetting process of insulation so

Thermosetting types of insulation are of two types:
• RESIN RICH SYSTEM OF INSULATION
• RESIN POOR SYSTEM OF INSULATION

The various types of materials used in the resin rich and resin poor process are given below.
Let us have an overview.
Materials used in resin poor system:

MATERIAL FOR RESIN POOR

DIAMOND COILS HALF BARS

• Treated trivoltherm • EPOXY glass cloth
• Impregnated polyester fleece • Nomex glass fleece
• Glass mat with accelerator • Fine mica polyester glass cloth
• Hostofon folium • Nomex
• Synthetic fibre tape • Form micanite
• Resin poor mica tape • Form mica tape
• Polyester fleece tape with graphite • Copper foil
• Semiconductor asbestos tape • Polyester fleece tape with
• Polyester glass tape graphite for ICP
• Polyester fleece tape • Polyester fleece for OCP
• Nomex polyamide adhesive tape • Polyester fleece tape with silicon carbi
• Mica splitting tape
VARNISH
• Polyester glass tape
• Rutapox
• Hardener (H-90)

A.4 materials used in resin poor process

8.3 RESIN RICH SYSTEM:

In olden days, Resin Rich system of insulation is used for all Electrical Machines. In
insulator contains nearly 40% of EPOXY RESIN, so it gives good thermal stability Resin Rich
Insulation consists of the following materials in percentage
1. MICA PAPER TAPE -40-50%
2. GLASS PAPER TAPE-20%
3. EPOXY RESIN-40%
 47

The bars are insulated (or) taped with RESIN RICH TAPE and place in the Pre-assembled
stator core including stator frame.
MATERIAL FOR RESIN RICH BARS
• Preprag
• Nomex
• Epoxy resin rich mica tape
• Glass tape
• PTFE tape
VARNISH
• Mica powder
• Graphite powder
• Conductive varnish
• Semiconductor varnish

A.5 Materials used in resin rich process:

In resin rich system of insulation Mica paper will give a good dielectric strength and Glass fiber tape
will give a good mechanical strength and Epoxy resin can withstand up to 155 degree Centigrade so it
gives a good thermal properties. Resin rich and Resin poor insulating materials are characterized by
the contact of the Epoxy Resin. In Resin rich system the content of Epoxy Resin tape is 40% so it is
named as RESIN RICH SYSTEM, and in Resin poor system the content of Resin tape is 8%. By VIP
impregnation process, the required amount is added to then conductor bars after assembling the core
and placing the winding in the core. In resin rich system before placing of coils in the stator slots the
rich tape will be wrapped over the bars. Nevertheless, this system has the following disadvantages:
1. This system is very time consuming and very long procedure.
2. Total cost of the system is more.

In order to minimize the over all cost of the machine and to reduce the time cycle of the system, the
VACUUM PRESSURE IMPREGNATION SYSTEM is being widely used. This process is very
simple, less time consuming and lower cost.
BHEL, HYDERABAD is equipped with the state of the art technology of VACUUM
PRESSURE IMPREGNATION.
The core or coil building and assembling method depends on the insulation system used. The
difference in core building is
1. For Resin rich insulation system the laminations are stacked in the frame itself.
2. For Resin poor insulation system (VPI) cage core of open core design is employed.
The manufacturing of coils also differs for both as explained above for core.
1. For resin poor process
2. For resin rich process
 48

MANUFACTURE OF STATOR COILS:

Manufacturing of stator coils depends on the type of the insulation process used for the stator.
I.e. the process is different for resin rich and resin poor process although few of the sub processes are
same for both.

9.1 For resin poor process:

In this process the high voltage insulation is provided according to the resin poor mica base of
thermosetting epoxy system. Several half overlapped continuous layers of resin poor mica tape
are applied over the bars. The thickness of the tape depends on the machine voltage.

9.1.1 Reception of copper

conductors:
The copper conductors rolls are
received is checked for physical and
mechanical properties. First piece is
checked for specifications such as
length and if found satisfactory, mass
cutting to desired length is carried out
by feeding into the cutting mills. B13 Side View showing one way of transposing insulated strands in
stator bar.

9.1.2 Transposition:
Conductors are adjusted one over another for a given template and the bundles are
transposed by 360 degrees by setting the press for “Roebel Transposition”. Now they are bundled and
consolidated by tying with cutter tape at various places.
Similarly all the bundles are processed. Thus each stator bundle has a transposed coils in each phase
such that the flux distribution is equal and hence the induced e.m.f.

9.1.3 Putty operation:

All the transposed bars are shifted to putty operation. Here a single bar is taken for putty
operation by filling up the uneven surfaces on the width face by filling with NOMAX. I.e., NOMAX
sheets are inserted in the crossovers on the width face to the both ends. Form mica net is placed over
the width face of the bar on both sides & wrapped with PTFE (poly tetra flamo ethane) tape.

9.1.4 Stack consolidation:

Now 2 to 3 bars are inserted into hydraulic presser and they are pressed horizontally and
vertically to a pressure up to 150kg/cm2. At the same time the bars are subjected o heating from 140
 49

to 160 degrees for duration of 2-3 hrs. Then the bars are unloaded and clamped perfectly. Now inter
half and inter strip testing is carried out and the dimensions are checked using a gauge.

9.1.5 Bending:
Each of the samples is placed over the universal former & the universal former is aligned to
the specifications. The bar is bent on both the sides i.e. on turbine side (TS) and exciter side
(ES).the 1st bend and the 2nd bend is carried out and continued by over hang formation. Now the
3rd bend is carried by inserting nomax sheet from the end of straight part to the end of 3 rd bend and
the bars are clamped tightly. Now the clamps are heated to 60 degrees for 30mins. Inter half and
inter strip tests follows.
9.1.6 Final taping:
The taping may be machine or manual taping and the taping is done according to
the type of insulation used. In case of resin poor system, resin poor tape is wrapped by 9*1/2 over
lap in the straight portion up to overhang and 6*1/2 over lap layers in the intermittent layers. The
intermittent layers are follows….
1st intermittent layer is ICP (internal corona protection) tape. This is wrapped by
butting only in straight portion.
2nd is split mica tape. One layer of split mica is wrapped by butting & using
conductive tape at the bottom so that split mica is not overlapped.
Next layer is O.C.P (outer corona protection). OCP tape is wrapped final in straight
portion by but joint up to end of straight portion on both the sides.
Next intermittent layer is ECP (end corona protection). ECP tape is wrapped from
the end of straight portion up to over hang over a length of 90-110mm. Now the bars are
wrapped
finally with hyper seal tape from straight portion to the end of 3rd bend in overlapping layers for
protecting the layers from anti fingering. The IH & IS tests follows and the bars are discharged to
the stator winding.

9.2 For Resin rich system:

The coil manufacture is same as
in case of resin poor but differ in a few
stages. The Conductor cutting and
material used is same as resin poor
 50

system. Transposition is done same as that of resin poor system. Stacking of coils is done. In this case
high resin glass cloth is used for preventing inter half shorts. There is a difference in putty work.
B.14 Cross-section of a multi turn coil, where three turns and three strands per
turn.

9.2.3 Putty work:

Nomex is used in between transposition pieces. 775 varnish is applied over the straight
portion of bar and mica putty is applied on the width faces of the bars.
Mica Putty mixture is a composition of SIB 775 Varnish, mica powder and china clay in the ratio of
100:50:25.
Straight part baking is done for 1hour at a temperature of 160°C and a pressure of 150kg/sq.cm.Then
bending and forming is done. Half taping with resin rich tape is done for over hangs and reshaping is
done. To ensure no short circuits half testing of coils is done.
9.2.4 Final taping:
Initial taping and final tapings is done with resin rich tape (Semica Therm Tape) to about 13-
14 layers. The main insulation layers are 12*1/2 overlap in the straight portion and 9 layers in the
overhang.
 51

B15 Layout of a mould used in baking of stator by Resin rich process

9.2.5 Final baking:

Final baking is done for 3hrs at a temperature of 160°C in cone furnace. The bar is fed into the
baking mould.
• The bar is heated for 1 hr at 90 degree to get gelling state.
• The temperature of the mould is increased to 110 degrees in 30 mins and simultaneously the
moulds are tightened. Now in this process 155 of the resin is oozed out only 25% will be
remain. Now the bar is unloaded and checked for final dimensions, sharp corners,
depressions, charring, hollow sounds etc.,
• Gauge suiting is done. I.e. the dimensions are made to compromising with the design.
• Conductive/graphite coating (643) is applied on the straight portion and semi-conductive
coating 642 from end of straight portion to 3rd bend to pre transition coating on both sides.1st
coating for 90mm, 2nd coating for 100mm and 3rd coating for 120mm on both sides.
• The bar is allowed for drying and epoxy red gel is applied from the end of straight portion to
the 3rd bend on both sides and allow for drying.
 52

• High voltage testing is done at 4 times that of rated voltage and tanδ testing, inter strip, inter
half testing are done. Tanδ values must be less than 2%.

10.An Overview
10.1 ADVANTAGES OF RESIN POOR SYSTEM OF INSULATION:
 It has better dielectric strength
 Heat transfer coefficient is much better
 Maintenance free and core and frame are independent
 It gives better capacitance resulting in less dielectric losses due to which the insulation life will be
more
 The cost will be less and it is latest technology
 Reduction in time cycle and consumption for MW also less and it gives high quality

10.2DISADVANTAGES OF RESIN POOR SYSTEM OF INSULATION:

• If any short circuit is noticed, the repairing process is difficult and need of excess resin from
outside.
• Dependability for basic insulating material on foreign supply

10.3ADVANTAGES OF RESIN RICH SYSTEM OF INSULATION:

 Better quality and reliability is obtained
 In case of any fault (phase - ground/ phase – phase short) carrying the repair process is very easy.
 Addition of excess resin will be avoided because of using resin rich mica tape

10.4DISADVANTAGES OF RESIN RICH SYSTEM OF INSULATION:

• It is a very long procedure
• Due to fully manual oriented process, the cost is more
• It is possible to process stator bars only.
Even though the advantages and disadvantages of both the process are explained above, resin
poor process is the best of all, as the resin content used is almost only 35% compared to resin poor
process and also show good insulation properties justified in the later sections.
11. Assembly of stator:
The completed core and the copper bars are brought to the assembly shop for
assembly.
11.1 Reception of stator core:
 53

Stator core after the core assembly is checked for the availability of foreign matter, so coil
projections are checked in each slot. HGL gauge is passed in each and every slot to detect bottom
core projections.
11.2 Winding holder’s assembly:
Assemble all the winding holders on both sides by adapting to the required design size.
Check all the wedge holders by a template and they are assembled as per the design requirement.
Tighten all the bolts relevant to winding holders and lock them by tag welding. Assemble HGL rings
on both the sides by centring with respect to core. Subject each individual for pressing in pressing
fixture at a pressure of 60 kg/cm2 for 30 minutes. Inter half test is conducted for each individual bar
before assembling into the stator.
Now stator bar assembling is carried out by centring to the core and check for proper
seating of bottom bars with T-gauge and checked for third bend matching, over hang seating etc..,
rein force the overhang portion of stator bars by inserting glass mat in between the bars and tying
them with neoprene glass sleeve. This process is carried out for all respective bottom bars .now the
pitch matching is checked on both sides both the generator and the exciter side.
Now high voltage testing is carried out on the stator.

11.3 Stiffeners assembly:

Stiffeners are assembled on both sides and then checked for physical feasibility of top bar
by laying into the respective slot. Check for uniform gap in the over hang and top bar matching to the
bottom bar pitch on both sides. Assemble all the top bars by inserting inner layer inserts and also
assemble relevant RTD’s (Resistance Temperature detectors) where ever they are required as per the
design.
After completion of top bars, reinforce overhangs by inserting Glass-mat and tying with
Neoprene glass sleeve and also check for the third bend matching on both the sides. Then the core is
subjected to high voltage DC test and inter half short circuit tests.

11.4 Eye formation:

Join bottom conductors and top conductors forming an eye, by brazing the conductors with
silver foil. Segregate eyes into two halves on both sides and test for inter half shorts. Insert Nomax
into two halves and close them.
Brazing makes the electrical connection between the top and bottom bars. One top bars strand
each is brazed to one strand of associated bottom bar so that beginning of the strand is connected with
out any electrical contact with the remaining strand. This connection offers the advantage of
minimizing three circulating currents.
 54

11.5 Connecting rings assembly:

The connecting rings are assembled on exciter side as per the drawing and connect all the
connectors to the phase groovers by joining and brazing with silver foil. Clean each individual phase
groove, insert nomax sheet and tape with semica folium. Subject the whole stator for HVDC test.
Terminate the three RTD’s in the straight portion and the 3-RTD’s in the over hang portion on both
turbine and exciter side except one for earthing requirement.

11.6 Phase connectors:

The phase connectors consist of flat copper sections, the cross section of which results in a low
specific current loading. The connections to the stator winding are of riveted and soldered tape and
like wise wrapped with dry mica/glass fabric tapes. The phase connectors are firmly mounted on the
winding support using clamping pieces and glass fabric tapes.

Thus we have a completed stator here. Now this stator is sent for VPI process because in there is a
chance of damage to the insulation due to the following reasons
 During the stator assembly, the bars are beaten with rubber hammers to fit into the slots
 Also there is a chance of void spaces in between the stator conductors and the core due to the
use of solid insulating materials, which lead to slot discharges.
So in order to fill these voids and to gain good insulating properties the stator is VPI processed. Let
us start with an introduction to the process and the early materials used for this process and the
advancement of this process to our present resin poor VPI process.
 55

12.THE VPI PROCESS

12.1 INTRODUCTION TO VACUUM PRESSURE IMPREGNATION SYSTEM (VPI)

12.2 HISTORY

DR. MEYER brought the VPI system with the collaboration of WESTING HOUSE in the
year 1956. Vacuum Pressure Impregnation has been used for many years as a basic process for
thorough filling of all interstices in insulated components, especially high voltage stator coils and
bars. Prior to development of Thermosetting resins, a widely used insulation system for 6.6kv and
higher voltages was a Vacuum Pressure Impregnation system based on Bitumen Bonded Mica Flake
Tape is used as main ground insulation. After applying the insulation coils or bars were placed in an
autoclave, vacuum dried and then impregnated with a high melting point bitumen compound. To
allow thorough impregnation, a low viscosity was essential. This was achieved by heating the
bitumen to about 180°C at which temperature it was sufficiently liquid to pass through the layers of
tape and fill the interstices around the conductor stack. To assist penetration, the pressure in the
autoclave was raised to 5 or 6 atmospheres. After appropriate curing and calibration, the coils or bars
were wound and connected up in the normal manner. These systems performed satisfactorily in
service provided they were used in their thermal limitations. In the late 1930’s and early 1940’s,
however, many large units, principally turbine generators, failed due to inherently weak thermoplastic
nature of bitumen compound.
Failures were due to two types of problems:
c. Tape separation
d. Excessive relaxation of the main ground insulation.
Much development work was carried out to try to produce new insulation systems, which
didn’t exhibit these weaknesses. The first major new system to overcome these difficulties was
basically a fundamental improvement to the classic Vacuum Pressure Impregnation process. Coils and
bars were insulated with dry mica flake tapes, lightly bonded with synthetic resin and backed by a
thin layer of fibrous material. After taping, the bars or coils were vacuum dried and pressure
impregnated in polyester resin. Subsequently, the resin was converted by chemical action from a
liquid to a solid compound by curing at an appropriate temperature, e.g. 150°C. this so called
thermosetting process enable coils and bars to be made which didn’t relax subsequently when
operating at full service temperature. By building in some permanently flexible tapings at the
evolutes of diamond shaped coils, it was practicable to wind them without difficulty. Thereafter,
 56

normal slot packing, wedging, connecting up and bracing procedures were carried out. Many
manufacturers for producing their large coils and bars have used various versions of this Vacuum
Pressure Impregnation procedure for almost 30 years. The main differences between systems have
been in the types of micaceous tapes used for main ground insulation and the composition of the
impregnated resins. Although the first system available was styrenated polyester, many developments
have taken place during the last two decades.
Today, there are several different types of epoxy, epoxy-polyester and polyester resin in
common use. Choice of resin system and associated micaceous tape is a complex problem for the
machine manufacturer.
Although the classic Vacuum Pressure Impregnation technique has improved to a significant
extent, it is a modification to the basic process, which has brought about the greatest change in the
design and manufacture of medium-sized a.c. industrial machines. This is the global impregnation
process. Using this system, significant increases in reliability, reduction in manufacturing costs and
improved output can be achieved. Manufacture of coils follows the normal process except that the
ground insulation consists of low-bond micaceous tape. High-voltage coils have corona shields and
stress grading applied in the same way as for resin-rich coils, except that the materials must be
compatible with the Vacuum Pressure Impregnation process. Individual coils are inter turn and high-
potential-tested at voltages below those normally used for resin-rich coils because, at the un-
impregnated stage, the intrinsic electric strength is less than that which will be attained after
processing. Coils are wound into slots lined with firm but flexible sheet material. Care has to be taken
to ensure that the main ground insulation, which is relatively fragile, is not damaged. After inter-turn
testing of individual coils, the series joints are made and coils connected up into phase groups. All
insulation used in low-bond material, which will soak up resin during the impregnation process. End-
winding bracing is carried out with dry, or lightly treated, glass-and/or polyester-based tapes, cords
and ropes. On completion, the wound stator is placed in the Vacuum Pressure Impregnation tank,
vacuum-dried and pressure-impregnated with solvent less synthetic resin. Finally, the completed unit
is stoved to thermo set all the resin in the coils and the associated bracing system.
After curing, stator windings are high-potential-tested to the same standard. Loss-tangent
measurements at voltage intervals up to line voltage are normally made on all stators for over 1kv. A
major difference between resin-rich and vacuum pressure impregnation lies in the importance of this
final loss-tangent test; it is an essential quality-control check to conform how well the impregnation
has been carried out. To interpret the results, the manufacturer needs to have a precise understanding
of the effect of the stress-grading system applied to the coils. Stress grading causes an increase in the
loss-tangent values. To calculate the real values of the ground insulation loss-tangent, it is necessary
to supply from the readings the effect of the stress grading. For grading materials based on the
 57

materials such as silicon carbide loaded tape or varnish, this additional loss depends, to a large extent
upon the stator core length and machine voltage.

VPI is a process, which is a step above the conventional vacuum system. VPI includes
pressure in addition to vacuum, thus assuring good penetration of the varnish in the coil. The result is
improved mechanical strength and electrical properties. With the improved penetration, a void free
coil is achieved as well as giving greater mechanical strength. With the superior varnish distribution,
the temperature gradient is also reduced and therefore, there is a lower hot spot rise compared to the
average rise.

In order to minimize the overall cost of the machine & to reduce the time cycle of the
insulation system vacuum pressure Impregnated System is used. The stator coils are taped with
porous resin poor mica tapes before inserting in the slots of cage stator, subsequently wounded stator
is subjected to VPI process, in which first the stator is vacuum dried and then impregnated in resin
bath under pressure of Nitrogen gas.
The chemical composition of our resin type and its advantages are explained in the later
sections. Now let us discuss the various stages involved in VPI process for resin poor insulated jobs.
VPI process is done in the VPI camber. For higher capacity stators of steam turbine or gas
turbine generator stators, horizontal chamber is used where as vertical chamber is used for smaller
capacity systems such as Permanent Magnet Generator (PMG), coil insulation of small pumps and
armature of motors etc..,

12.3 Vacuum Pressure Impregnation of resin poor insulated jobs:

VPI process for a stator involves the following stages.
2. Preheating
3. Lifting and shifting
4. Vacuum cycle
5. Vacuum drop test
6. Heating the resin
7. Resin admission.
8. Resin settling
9. Pressure cycle
10. Aeration.
11.Post curing cycle
12.Cleaning
 58

12.3.1 General instructions before VPI process:

The jobs that are entering tank for Vacuum Pressurised Impregnation shall not have any oil
based coatings. Any such, rust preventive/ corrosion preventive viz., red oxide etc., shall be
eliminated into the tank. Jobs shall be protected with polyethylene sheet for preventing dust or dirt on
jobs, till it is taken up for impregnation. Resin in the storage tank shall be stored at 10 to 12°C and
measured for its viscosity, viscosity rise. Proper functioning of the impregnation plant and curing
oven are to be checked by production and cleared for taking up of job for impregnation.

12.3.2 Pre heating:

The foremost stage of VPI, the completed stator is placed in the impregnation vessel and kept
in an oven for a period of 12 hours at a temperature of 60 deg. Six thermocouples are inserted at the
back of the core to measure the temperature. The temperature should not exceed to 85 deg .Smaller
stator can be inserted directly into the impregnation chamber . The job is to be loaded in the curing
oven and heated. The temperature is to be monitored by the RTD elements placed on the job and the
readings are logged by production. The time of entry into the oven, time of taking out and the
temperature maintained are to be noted. Depending on convenience of production the jobs can be
preheated in impregnation tank by placing them in tubs.
The impregnation tubs used for impregnation of jobs are to be heated in the impregnated tank itself,
when the jobs are preheated in the curing oven
 59

12.3.3 Insertion of tub with job into the impregnation tank:

The wound stator is lifted and shifted into the tub. By the time, the preheating of job is completed, it
is to be planned in such a way that the heating of tub and tank heating matches with the job. This is
applicable when the job is heated in the curing oven separately. The preheated job is to be transferred
into the tub by crane handling the job safely and carefully with out damage to the green hot insulation
the tub is then pushed in the 140 tank furnace or also called as vacuum tank, after which the lid is
closed and the tank furnace was heated to 60 +/- 3 deg The warm tub with job is inserted into
impregnation tank by sliding on railing, in case of horizontal tank. The thermometer elements are to
be placed at different places on the job. The connection for inlet resin is to be made for collection of
resin into tub. After ensuring all these lid of the impregnation tank is closed. In case of vertical tank
the job along with tub is slinged and inserted carefully into impregnation tank without damage to
insulation
12.3.4 Vacuum cycle:
The pre heated job will be placed in the impregnation chamber by a hydraulic mechanism.
The vessels are kept clean and the resin available in the vessel is wiped out. Methylene and traces of
resin should not be allowed on the inner side of the tank. Now the vacuum pumps are all switched on
and a vacuum pressure of about 0.2 mb is maintained for about 17 HRS, after which the wound stator
is subject to vacuum drop test.

12.3.5 Vacuum drop test:

This drop test is important phase, all the vacuum pumps are switched off for about 10 mins,
and the vacuum drop is measured and it is checked whether it exceeds 0.06mb, if it exceeds 0.06mb
then it is subject to repetition of vacuum cycle for another 6 to 8 hrs, else it is sent to the next cycle

12.3.6 Drying the job in vacuum

The job is to be dried under vacuum. Drain out the condensed moisture/ water at the exhausts
of vacuum pumps for efficient and fast vacuum creation. Also check for oil replacement at pumps in
case of delay in achieving desired vacuum.

12.3.7 Heating the resin in the storage tank

The completion of operations of drying and the heating of the resin in the storage tank are to
be synchronised. The heating of resin in the tank and pipeline is to be maintained as at preheating
temperature .i.e. the temperature is maintained at 60+/- 3 deg ,including pipeline

12.3.8 Admission of resin into impregnation tank

The resin is allowed into the impregnation tank tub if required from various storage tanks
one after the other, such that the difference in pressure fills the tank, up to a level of 100mm above
the job generally, after which the resin admission is stopped. After 10mins of resin settling the tank is
 60

to be pressurised by nitrogen. While admitting resin from storage tanks pressurise to minimum so that
nitrogen will not affect resin to spill over in tank.

12.3.9 Resin settling:

The resin is allowed to settle for about 4mins in such a way that bubble formation ceases

12.3.10 Impregnation
Pressurising/gelling
After the resin has settled the job
is subject to pressure cycle of 4 kg/ cm2
of dry nitrogen into the vacuum tank
after obtaining 4 kg/cm2, this is subject
for 2 hrs. in this stage the resin is
impregnated into the micro pores of the
stator and is very firmly embedded into
the crevices of the stator ,so thus acting
as a tough layer of insulation for the
stator ,being indestructible in the long run. B16 vertical VPI
tanks for smaller jobs

12.3.11 Withdrawal of resin from

impregnation tank to storage tank
The resin that is pressurised as
per pressure cycle is drawn into the
tank by the opening of relevant valves
will allow the resin to come back to
the storage tank. The job also shall be
allowed for dripping of residue of
resin for about 10min. After dripping, withdrawal of resin in various storage tanks is to be carried out.
This is necessary because resin is a very costly material.
 61

12.3.12 Taking out the tub with job from impregnation tank
The lid is then opened after taking precautions of wearing mask and gloves for the operating
personnel as a protection from
fumes. The job is withdrawn from
impregnation tank by
sliding on railing for horizontal
and slinging on to crane for
vertical impregnation tanks.

12.3.13 Post curing:

The job is post heated. The
time and temperature to which
the job has to be scheduled is varies
according to the type of job and is
given in the table. The time at which the heating is started, achieved and maintained is to be logged.
The wound stator is subject to 140 +/- 5 deg. After obtaining 140 deg the stator is subject for 32 hrs.
The stator is then made to rotate at 1 rpm up to 120 deg. It is then allowed for cooling without
opening the doors till the temperature reaches 80 deg, after attaining the temperature of 80 deg, the
doors are opened and wound stator is sprayed with epoxy red gel on the overhangs and is allowed for
drying.

12.3.14 Cleaning:
Entire wound stator is cleaned for resin drips, after which its subjected to HV and tan delta tests
12.4Electrical testing:
All jobs that are impregnated till above process are to be tested for electrical tests. After
ensuring that all the temperature/vacuum conditions stipulated for drying, impregnation and curing
operations have been properly followed, the job is to be released for this operation.
12.5Global processing:
Processing details depends very much on the machine type, on customer’s defined parameters and
type of mica tapes.
Generally the VPI system is used in impregnation vessels up to 30T where the rotor/stator is
impregnated at elevated temperatures. Machine parts usually are preheated (also under vacuum) in
order to remove moisture and to reduce viscosity during impregnation.
12.6 Resin management:
After impregnation the VPI bath is pumped into storage tanks and cooled down to 5-10°C and
should be stored in dry conditions in order to obtain a long bath life. Actual bath life depends on
additional parameters, e.g., impregnation temperature and duration of impregnation, impurities in the
 62

bath, wash-out of catalyst from mica tapes into the un- accelerated resin system (B), replenishment
rate, moisture exposure etc,. The viscosity of the bath should be checked periodically in order to
maintain a suitable viscosity for impregnation.
Impregnated, yet uncured machine parts in unconditioned atmosphere may pickup moisture.
Therefore curing directly after
impregnation or storage in moisture
controlled area is recommended.
Generally machine parts are rotated
when removed
B17 Showing
the resin tank in which resin is
stored.
from the bath and during the first part of
curing in order to avoid drip off.
Evaporation of hardener during the
vacuum cycle leads to a change in the resin/hardener ratio in the bath and has to be compensated.
Therefore replenishment is mixing ratios of 100-120pbw of hardener HY 1102 per 100pbw MY 790-1
are generally used. Replenishment mixing ratios depend on actual processing parameters and
conditions and have to be evaluated at the customer site.
Due to excellent latency of the system (A) MY 790-1/HY 1102/DY 9577/DY073 the replenishment
volume to maintain a constant viscosity is comparatively small, even if impregnation is performed at
40-50°C.
On single coils and roebel-bars the mica insulation is normally covered with a tight glass tape to
prevent drainage of the impregnation resin.
12.7 Specific Instructions:
Depending on the insulation materials and the accelerating agent in use, a ramped curing
schedule is recommended.
In systems with high reactivity, where the accelerator can be include in the mica-tape, a fast
gelation can be obtain with a temperature-shock, and draining can so be reduced or avoided.
Standard curing with the standard accelerated mixture (system A) is:
11 at 90°C plus 18 h at 140°C
12.8 Precaution:
To determine whether cross linking has been carried to completion and the final properties are
optimal, it is necessary to carry out relevant measurements on the actual object or to measure
the glass transition temperature. Different gelling and cure cycles in the manufacturing
process could lead to a different cross linking and glass transition temperature respectively.
 63

12.9 Features and Benefits:

• State-of-the-art process for completely penetrating air pockets in winding insulation.
• Increases voltage breakdown level. (Even under water!)
• Proven submergence duty system
• Improved heat transfer- windings are cooler, efficiency is improved.
• Improves resistance to moisture and chemicals.
• Increases mechanical resistance to winding surges.

An overview of entire VPI process with the time taken for each process according to the type of the
job used is given below in a tabular form
Vacuum Pressure Impregnation of resin poor insulated jobs:

Variant Description

01 Brushless exciter armature, PMG stators and

Laminated rotors

02 Stator wound with diamond pulled coils.

3 Stator with half coils

Any other
Variant-01 Variant-02 Variant-03
information
60±3°C for
60±5°C for 12hrs
Preheating 60±5°C for 12hrs
3hrs

<0.2mbar
(both together
Vacuum to be shall not
0.4mbar 0.2mbar/0.4mbar
maintained exceed 50hrs
including
rising time)
Stopping
vacuum
pumps for
10min shall
check 17hrs
Vacuum heating 0.2mbar for 9hrs
vacuum drop.
time 3hrs 0.4mbar for 17hrs
The vacuum
drop shall not
exceed by
0.06mbar for
10min
Increase in
40min 80min 80min
pressure
 64

Maximum
3bar 4bar 4bar
pressure
Pressure
3hrs 3hrs 3hrs
holding
At140±5°C for At140±5°C for At140±5°C
Post curing
14hrs 32hrs for 32hrs
A.6 Table showing temperature and time to be maintained for different type of jobs in VPI
13. FACILITIES AVAILABLE IN VPI PLANT IN BHEL:
The major facilities available in VPI plant are:
 Steam furnace for preheating
Size of chamber: 2 * 2 * 6.5 M
Maximum temperature: 160°C
Electrical power consumption: 75KW
Work place: 1425
Work centre: 3215
Stream inlet: 200-250°C
 Impregnated tubs for keeping jobs
For vertical impregnation: As per respective tech. Document.
For horizontal impregnation: As per respective tech. Document.
 Specifications of plant:
• Impregnation medium
(a) Epoxy resin (class F solvent free) and hardener mix in 1:1 ratio as per TG34967
(b) Epoxy resin (class F solvent free) and hardener mix in 1:1 ratio as per TG34931
• Horizontal impregnation chamber
Diameter: 4000mm
Cylindrical length: 9000 mm
Operating over pressure: 6 bar
Operating vacuum: 0.15 mbar
Operating temperature: 90°C
Loading weight of impregnation object: maximum of 120 tonnes
Maximum leakage rate: less than 1mbar/lit/sec.
Moving load: 140 tonnes.
Static load: 170 tonnes
• Pressure medium for impregnation
Pressure medium: dry nitrogen
Operating pressure: 6 bar.
Nitrogen storage capacity: 52cubic meter at 25 bar.
 65

• Resin storage capacity

Total storage: 5*9000L+1*3000L
• Operating parameters of each tank
Operating vacuum: 0.5mbar
Operating over pressure: 0.5bar
Operating temperature: 80°C
• Resin filters(stainless steel washable)
Filter fineness: 150microns
Output (maximum): 1000lits/min
• Vacuum system
Root pumps: 2No.s, 5.5KW each
Suction capacity: 2000cubic meter/hr
• Vacuum pumps(4No.s, 7.5KW each)
Suction capacity: 250 cubic meter/hr
This system is provided with separator filter with activated carbon filters, to protect the vacuum
pumps from resin and hardener vapours.
• Refrigeration system
The resin inside the tanks has to be stored at 10±2°C. this can be stored for indefinite period with
a brine chilling/refrigeration system.
The brine storage capacity: 1*25000L+1*26000L
Composition of brine: 40%Mono Ethylene glycol and 60%water
• Heating and cooling system
The heating of resin in the storage tanks and the impregnation chamber is by circulating the
heated brine through the heat exchangers, to heat by saturated steam. The hot brine is cooled to
about 40°C by circulating water through coolers and then the brine is chilled to -10°C and stored
in the tanks.
 Post heating of job
(a) Explosion proof steam drier and electrical heating superposed.
Size: 7*4.5*4.5M
Maximum weight of job: 80 tonnes
Maximum temperature: 150°C
(b) Indirectly heated hot air circulating oven (gas fired)
Size: 9*4.5*4.5M
Maximum weight of job: 170 T/120T with facility for rotation.
Maximum temperature: 150°C
 66

13.1 DATA COLLECTION OF SAMPLES

During the project two jobs have been impregnated in VPI Plant, the data has been collected and
recorded in the project report.

13.1.1 INDO-BHARAT-II ROTOR

Preheating:
Indo Bharat II rotor is loaded for preheating in steam furnace on 30-5-2007 at 18:00hrs.
RTD-I(°C) RTD-II(°C) Furnace air Remarks
Date and time temperature
Rotor
temperature is
reached to 60±3
°C at 2:00hrs
30.5.2007 19:00 32.0 30.0 45.6 on 31.5.2007
and it is
maintained for
4 hrs i.e., up to
6:00 on
31.5.2007
30.5.2007 20:00 45.4 48.6 57.9
30.5.2007 21:00 49.9 50.9 63.4
30.5.2007 22:00 52.5 54.3 70.5
30.5.2007 23:00 53.3 55.1 73.4
Rotor is
switched to vac
30.5.2007 24:00 56.6 57.3 75.6 140 tank at 7:00
hrs on
31.5.2007
31.5.2007 1:00 59.9 60.2 75.1
31.5.2007 2:00 62.4 63.9 77.0
31.5.2007 3:00 62.3 64.7 77.0
31.5.2007 4:00 63.3 64.1 75.0
31.5.2007 5:00 63.3 64.0 75.6
31.5.2007 6:00 63.1 63.7 75.6
A 7 PREHEATING OF INDO BHARATH II ROTOR
 67
Room
RTDI(°C) RTDII(°C) temperature Remarks
(°C)
Date and time
31.5.2007 19:30 62.0 62.0 36.0 Resin tank 025 is heated
for impregnation
31.5.2007 21:30 70.1 69.2 36.7
31.5.2007 23:30 86.2 81.6 36.7
1.6.2007 1:30 101.5 97.6 35.6 Resin admission started
at 14:10 hrs on
31.5.2007
1.6.2007 3:30 116.2 113.1 34.8 Resin admission
completed at 14:25 hrs
on 31.5.2007
1.6.2007 5:30 129.6 125.7 33.8 Pressurization started at
14:45 hrs on 31.5.2007
1.6.2007 7:30 137.6 133.2 33.2 Pressurization
completed at 15:30hrs
on 31.5.2007
1.6.2007 9:30 145.7 140.2 36.5 Pressurization hod up
completed at 18:30hrs
on 31.5.2007
1.6.2007 11:30 145.7 141.6 38 Resin withdrawal to
storage tanks is from
18:30 to 18:45hrs on
31.5.2007
1.6.2007 13:30 144.7 143.4 42.8 Rotor loaded in gas
furnace at 19:15hrs on
31.5.2007
1.6.2007 15:30 144.1 143.0 43.8 Rotor temperature is
reached to 131.6 to
145.7°C at 8:30hrs on
1.6.2007 and it is
maintained for 14hrs
i.e., up to 22:30hrs on
1.6.2007
1.6.2007 17:30 144.0 144.5 42.8
1.6.2007 19:30 143.0 143.0 41.0 Furnace is switched at
22:30hrs on 1.6.2007
and circulation fans are
kept running till the job
temperature is reached
to 70°C to 75°C.
1.6.2007 21:30 142.8 142.6 40.8
A.8 impregnation of Indo Bharath II rotor

Vacuum cycle:
Vacuum in Vacuum in Job
Date and time graph (mbar) meter temperature (° Remarks
(mbar) C)
 68

31.5.2007 7:00 -- -- 62.2

31.5.2007 8:00 -- 3.0 61.5
31.5.2007 9:00 0.85 0.86 61.3 Vacuum pump
31.5.2007 10:00 0.54 0.55 61.1 started at 7:30
31.5.2007 11:00 0.39 0.4 61.1 hrs on
31.5.2007 12:00 0.38 0.4 61.1 31.5.2007.
31.5.2007 13:00 0.37 0.4 61.0
31.5.2007 14:00 0.36 0.39 61.0
A.9 vacuum cycle of Indo Bharath II rotor

RESIN CYCLE AND POST CURING CYCLE:

13.1.2 INDO-BHARAT-II STATOR:

Preheating:
Indo-Bharat-II stator is loaded for preheating in steam furnace on 7-5-2007 at 23:30hrs.
Date and Time RTD-I(°C) RTD-II(°C) Furnace air
Remarks
temperature(°C)
7.5.2007 23:30 36.3 36.1 Stator temperature is
reached to 60.5°C to
62.9°C(60±3°C) at
7:30hrs on 8.5.2007
and it is maintained
for 12hrs i.e., up to
19:30hrs on 8.5.2007
8.5.2007 1:30 43.6 42.9
8.5.2007 3:30 52.0 51.74
8.5.2007 5:30 55.9 56.0
8.5.2007 7:30 60.5 62.9 Stator is loaded in
vac(140) tank at
21:00hrs on
8.5.2007
8.5.2007 9:30 61.3 62.9
8.5.2007 11:30 60.3 62.4
8.5.2007 13:30 60.3 62.6 Vac. Pump is started
at 2:30hrs on
9.5.2007
8.5.2007 15:30 62.5 62.9
8.5.2007 17:30 62.9 62.66
8.5.2007 19:30 62.4 62.1
A.10 Preheating of Indo Bharat II stator

Vacuum cycle:
 69

Vacuum in Vacuum in Job

Date and Time Resin cycle
graph (mbar) meter (mbar) temperature (°
C)

8.5.2007 22:00 -- -- 54.37 Resin tanks 025,102 are

heated for impregnation
8.5.2007 0:00 -- -- 54.89 Viscosity of resin at 60°C
is 33CP
9.5.2007 2:00 -- -- 59.02 Viscosity after aging is
36.10CP
9.5.2007 3:30 0.65 0.65 61.6 9.5.2007 and 10.5.2007
9.5.2007 5:30 0.41 0.40 63.59 Resin admission started at
19:45hrs
9.5.2007 7:30 0.28 0.29 64.2 Resin admission
completed at 19:55hrs
9.5.2007 9:30 0.22 0.22 63.2 Pressurisation started at
20:00hrs
9.5.2007 11:30 0.19 0.19 62.3 Pressurisation of
4kg/sq.cm reached at
21:20hrs
9.5.2007 13:30 0.18 0.18 62.1 Pressurisation hold up for
3hrs is at 0:20hrs
9.5.2007 15:30 0.17 0.17 62.0 Resin withdrawn to
storage tanks is from
0:30hrs –1:00hrs
9.5.2007 17:30 0.14 0.14 61.8 Stator loaded in hot air
furnace from 1:00hrs –
1:30hrs on 10.5.2007
9.5.2007 19:30 0.14 0.14 61.3

A.11 Vacuum cycle of Indo Bharat II stator

Post curing:

Date and ESOH TSOH ESW TSW Room

Core Remarks
Time 15T 06B 02 13 temperature
 70

10.5.2007
70.0 76.4 62.4 62.5 63.4 33.1
1:30hrs
10.5.2007
126.7 131.4 94.7 102.3 98.8 31.7
4:30hrs
10.5.2007
144.3 154.1 125.4 134.5 126.1 31.6
7:30hrs
10.5.2007
147.7 154.9 139.9 145.1 140.6 34.8
10:30hrs
10.5.2007
137.6 144.4 139.3 141.6 140.7 38.0
13:30hrs
10.5.2007
136.9 144.2 140.0 140.9 140.6 38.4
16:30hrs
10.5.2007
140.2 143.6 140.1 140.7 140.2 37.2
19:30hrs
Job temp. is reached to
140±5°C i.e., from 136.2°
C to 145.6°C at 9:30hrs
on 10.5.2007 and it is
maintained for 32hrs i.e.
10.5.2007 up to 17:30hrs on
144.4 151.3 143.7 145.1 144.1 35.9
22:30hrs 11.5.2007.
11.5.2007
143.1 146.7 145.2 145.1 145.2 33.8
1:30hrs
11.5.2007
144.3 151.0 143.6 144.0 144.7 31.1
4:30hrs
11.5.2007
135.7 142.1 144.3 145.1 145.0 31.3
7:30hrs
11.5.2007
135.0 135.7 135.1 135.0 135.8 34.8
10:30hrs
11.5.2007
135.6 141.4 135.4 135.6 135.9 38.3
13:30hrs
Furnace is switched
off at 17:30hrs on
11.5.2007 and
circulation fans kept
running till the job
11.5.2007 temperature is
148.0 149.2 142.8 142.2 142.1 39.8
17:30hrs reached from 70°C-
75°C
A.12 Post curing of Indo Bharat II stator
 71

13.1.3 High voltage levels of stator/rotor windings for multi turn machines:

S.No. Description HV level HV in kv remarks

Stator winding

1. After laying 18.9/1’ RTD,IT test

and wedging of
coils
2. After OH 18.03/3’ RTD,IT test
spacers and
forming eyes
3. Before 17.5/1’ R, RTD test
impregnation
4. After 26.0/1’ R, RTD, Tanδ,
impregnation leakage
reactance test
5. Customer 25.0/1’ Rotor winding
acceptance

Rotor winding

1. After laying UT+1400 2.9 Pole drops

first coil
2. After laying UT+1250 2.75 Pole drops
second coil
3. After laying UT+1100 2.6 Pole drops
third coil
4. After laying UT+950 2.45 Pole drops
fourth coil
5. After laying UT+800 2.3 Pole drops
fifth coil
6. After laying UT+650 -- Pole drops
sixth coil
7. After all -- -- R, Pole drops
connections
8. After tech. -- 2.15
rings assembly
9. After bandage -- 2.0 R, Pole drops
10. After -- 1.9 R, Pole drops
impregnation
11. After excitation -- 1.8 R, Pole drops
cable assembly
12. After balancing UT+200 1.7 R,Z with 50Hz

A.13 High voltage levels of stator/rotor windings for multi turn machines
 72

13.1.4 TESTING RESULTS OF INDO-BHARAT-II ROTOR

Customer name: INDO-BHARAT-II ROTOR

M/c rating: 10.8MW, 12kv, 1500rpm.

Test: Z, R and H.V test.

Stage: after impregnation.

Ambient temperature: 35°C

Ohmic resistance: 0.264Ω (rotor temperature was more)

Voltage( volts) Current(amps)

215.0 0.5
367.5 1.0
523.0 1.5

High voltage test:

IR value before H.V. test at 15”/60” -- 200/300 MΩ

H.V. applied at 1.9kv /1’ – withstood
IR value after H.V. test at 15”/60” -- 200/300 MΩ

13.1.5TESTING RESULTS OF INDO-BHARAT-II STATOR:

Customer name: INDO-BHARAT-II STATOR

M/c rating: 10.0MW, 12kv, 0.8pf, 650A, 1500rpm.

Test: H.V test.

Stage: after impregnation.

Ambient temperature: 36°C

A PHASE: IR value at 2.5kv

IR value before H.V. test -- 1000/2000 MΩ

H.V. applied at 26-25kv /1’ – withstood
IR value after H.V. test -- 1000/2000MΩ

B PHASE: IR value at 2.5kv

 73

IR value before H.V. test -- 1000/2000 MΩ

H.V. applied at 26-25kv /1’ – withstood
IR value after H.V. test -- 1000/2000MΩ

C PHASE: IR value at 2.5kv

IR value before H.V. test -- 1000/2000 MΩ

H.V. applied at 26-25kv /1’ – withstood
IR value after H.V. test -- 1000/2000MΩ

INDO-BHARAT-II STATOR:

Customer name: INDO-BHARAT-II STATOR

M/c rating: 10.0MW, 12kv, 0.8pf, 650A, 1500rpm.

Test: H.V test-RTD measurement, resistance measurement.

Stage: After impregnation.

Ambient temperature: 36°C

Excitation Side:

26 113.8Ω
10 114.0Ω
62 113.8Ω
50 113.8Ω
20 113.8Ω
38 113.9Ω
14 113.8Ω

Turbine Side:

49 125.0Ω
13 113.8Ω
25 113.9Ω
21 113.8Ω
61 113.8Ω
37 113.9Ω
1 113.8Ω

A-Aο --29.4mΩ
B-Bο -- 29.3mΩ
 74

C-Cο -- 29.4mΩ

14.COMPARISION BETWEEN RESIN POOR AND RESIN

RICH SYSTEMS:

RESIN POOR SYSTEM RESIN RICH SYSTEM

1. The insulation tape used in this system 1. The insulation tape used in this is 7% of
has 40% resin. 40% resin.
2. This method follows thermosetting 2. Same as in resin poor.
process.
3. There is a need for addition of resin from 3. Further addition of resin is not required
outside. from outside.
4. Reduction in time cycle for this process 4. It is very long process and
time consuming while at processing stage.
5. No tests are carried out while at 5. Tests are being carried out Stage.
processing
6. Processing of bars along with stator and 6. Processing of stator bars is
with conductors and processing of exciter only possible in resin rich
Coils along with exciter is possible. systems.
7. The cost of repair is more 7. Repairing work is easy.
8. The overall cost is less 8. The total cost in this process is more.
compared to resin rich system.

A.14 Comparison between resin rich and resin poor process

Applications:
• All critical machines
• Equipment exposed to frequent surges/starting
• Harsh or moist environments
• Motors that run at service factor

DRAWBACKS OF VPI SYSTEM:

 Number of RTD’s required are more

 The whole operation is time consuming
 75

 It depends largely on moisture and season of operation

 Maintenance of resin below room temperature about 8-12°C is complicated.

SUGGESTIONS:

Processed in a Clean Room Environment

To ensure optimum rewind integrity, all rewinds should be conducted in a clean,
temperature- and humidity-controlled environment. It ensures optimum material performance and
prevents dirt or moisture contamination during the process.

VPI Process Control

Throughout the VPI process, each stator is continuously monitored by computer to ensure
homogenous fill.

How can we say that the present VPI BY RESIN POOR process currently used in BHEL is a superior
process as compared to VPI by resin rich process ? inorder to find an answer to this question the
justification follows:

15. JUSTIFICATION
We can say that VPI by resin poor system is more superior to other types of insulation by conducting
HV and tan δ tests, and the results of which are clearly indicated in the graphs below:
After impregnation of the stator core by VPI process the following tests are conducted:
1. TAN δ TEST.
2. HIGH VOLTAGE Tests.

15.3.1 High Voltage test:

AC High voltage test is conducted on VPI system after impregnation to verify proper
impregnation and dielectric strength of insulation. This test was conducted at 105% of winding
test voltage i.e. Up=2Un+1KV Where Up-Winding test voltage Un-rated voltage of machine.

Equipment
 50 Hz A.C High voltage transformers and its induction regulator/input autotransformer.
 Potential transformer (35 or100KV/100V)
 Voltmeter
 Binding wire
 Earthing Rod and Earthing wire/cable
 76

When H.V test is done on one-phase winding, all other phase windings, rotor winding,
instrumentation cables and stator body are earthed.
The high voltage is applied to winding by increasing gradually to required value and maintance for
one minute & reduced gradually to minutes. The transformer is switched off & winding discharged to
earth by shorting the terminal to earth using earthing rod connected to earth wire/cable.
The test is conducted on all the phases & rotor winding separately.

HV Test Levels:
Stator winding: (2Ut+1) KV =23 for 11 KV machine
Rotor winding: (10 Up) volts (with min of 1500v & max of 3500v),
Where, Ut= Rated of machine under test Up= Excitation voltage.

15.3.2 TAN δ TEST:

Equipment: Schering Bridge
After impregnation and curing of the winding a dissipation factor Vs voltage measurement as
stipulated in the application national and international standard specification is performed for each
bar between all-individual phase winding to ground.

Guiding values for the deception factor and its rice with the voltage merely. Given in the
KEMA specification the maximum value should not exceed 0.001 at 20% of rated voltage and rise
shall not be greater than 0.006 per 20% of rated voltage up to 60% of rated voltage and 0.08 per 20%
of rated voltage up to a rated voltage.

Winding manufacture by the Vacuum Pressure Impregnation Process comply with these limits.

The above test results are specified in the following graphs. First graph shows that Voltage Vs Tan δ
curve, it shows different Tan values at different percentage of rated voltage 20%, 40%, 60%, 80%,
100% of rated voltage respectively.

The second graph is Stages of materials Vs life of insulation material, it shows that resin poor
system of insulation has very long life compared to resin rich system of insulation. At 10 KV the
resin poor system insulation as a lifetime of 540 years. Any good machine as life span of 25-30 years
by using this insulation we will get a very long life with standard machine.

This test is conducted to check the presence of impurities in the insulation & tanδ value for each
phase & also for combined phases is noted down. Tan δ value should be generally less than or equal
to 2%.
 77

TESTING RESULTS:
Rating: Vph (0.2Un ) Rated KV= 10.5KV , 3000RPM.

Wph Tan δ Tan δ Tanδ Tan δ

Wph uph vph Wph uph
vph
2.1 0.806 0.815 0.811 1.18
4.2 0.820 0.832 0.830 1.209
6.3 0.857 0.869 0.868 1.230
8.4 0.899 0.903 0.905 1.254
10.5 0.941 0.938 1.268

A.15 tan δ values of the different phases of a generator

Rating: 31.25, 250 MW, 11KV, 1640A, 0.8pf, 3000rpm.

SCC Testing:
Ia Ib %In If Vd Id Dm O/P
0 0 0 0.01 559.0 404.58 226.16
337.2 337.6 20.57 94.7 515.95 443.1 228.60
664.8 666.2 40.5 187.1 516.04 481.4 248.44

1005.8 1006.1 61.34 281.51 516.52 533.6 275.6

1324.9 1326.5 80.84 369.16 516.54 651.25 336.35
1495.2 1496.9 91.2 415.2 516.18 690.3 356.32
A.16 tabular form for short circuit currents and voltages
 78

OCC Testing:
Vab Vbc Vca %En If Vd Id Dm O/P
35.3 35.3 35.3 35.32 0.01 512.4 419.85 215.16
2281.2 2282.5 2281.8 20.74 40.44 512.93 423.15 216.62
4447.42 4441.4 4448.2 40.44 77.05 512.4 442.45 226.71
6662.0 6665.0 6663.0 66.58 116.65 512.3 466.43 288.95
8845.0 8849.0 8846.0 80.4 160.3 512.19 501.08 256.64
10015.0 10019.0 10017.0 91.06 186.56 512.25 517.25 264.93
A.17 tabular form showing open circuit voltages and currents obtained in the testing
 79

14.3.4. Graphs

TAN δ

KV
 80

Fig. 2
Comparative functional testing using the stator slot model confirms the progress achieved in extending the
service life of 13.8-kV insulation of varying compositions.

Resistance Measurement:
Instrument: Micro ohm meter
Resistance at 25°c (mΩ) Resistance at 20°c (mΩ)
Rotor 264 258.92

R75 = (( 235+75)/(235+20)) x R20= (310/255) x (0.2587)=0.3147 Ω

Rotor current = 562 A
Efficiency = (output)/(output+losses)
Losses = 99.532 + 9.9532 + 39.39 + 385.15 + 286. 38 = 820.40
Efficiency= (25000/25000 + 820 .40 ) = 96.82%

18.PRESENT INSULATION SYSTEMS IN THE WORLD

Four major manufacturing processes have been and are still widely used to form and consolidate
insulation systems for form-wound stators. They are:
1. Vacuum pressure impregnation (VPI) of individual coils and bars
2. Global VPI of complete stators
3. Hydraulic molding of individual coils and bars using resin-rich tapes
4. Press curing of individual coils and bars, also using resin-rich tapes
There are some combinations of these methods also in use. The binder resins can be
categorized as high- or low-solvent-containing and solvent less, as well as by their chemical nature.
Although no longer manufactured for coils in new stators, there are many machines still in service,
and expected to remain in use for several more decades, that are insulated with asphaltic mica
splitting.

There are four principal drivers that govern the selection of the insulation systems currently being
manufactured. They are:
1. Good service experience with earlier versions of the same basic system
2. Commercial availability of the materials to be used
3. Relative costs of the raw materials and processes in the competitive machine-sales environment
4. Design advantages or limitations each insulation system and process brings to the final generator or
motor for its expected service life and economy of operation
 81

New insulating materials may require the development of new or significantly modified
manufacturing processes to obtain the insulation system improvements inherent in the materials. By
the 1990s, the major insulation suppliers were offering full insulation systems, including the basic
processing know-how, to their customers. For smaller OEMs and most repair shops, the insulation
supplier’s materials, other acceptable materials, and processing specifications are all that is needed to
support work. The final insulation system may use the materials supplier’s trade name, e.g., VonRoll
ISOLA’s Samicatherm™ and Samicabond™.
Larger OEMs still work with insulation suppliers to optimize both the materials and processes for
new or changed insulation systems.
The first consideration in using modern insulation systems is the method of applying the
ground-wall materials to form-
wound stator coils and bars
discussed in previous sections, the
Haefley process was widely used
decades ago to apply wide sheets of
insulation material to coils.
Presently, however,
virtually all ground-walls are
fabricated by the application of
relatively narrow (2–3 cm wide)
B18 A modern stator bar taping machine that applies tape both
tapes. When tapes were first in the slot and end winding portions of the bar.
introduced, and for many decades thereafter, they were applied with hand by skilled tradesmen. There
are many companies into insulation manufacture, mainly all the companies have these insulation
systems as a trade secrets. So one cannot point out which is the best insulation system as there are
many factors such as availability in a particular country, so insulation systems are given different
names ,though the composition just differs a wee bit, so let us have a brief overview

16. Westinghouse Electric Co.: Thermalastic™

Westinghouse Thermalastic™, the first modern synthetic insulation system. The first
Thermalastic insulated generator went into service in 1950, in the 1960’s minor changes that were
made included introduction of glass cloth as a backing material for the mica, resin modifications to
help VPI resin tank stability, and improvements in the partial discharge suppression treatments on
generator coil surfaces. Although large turbine generators continue to use the individual bar
impregnation and cure method, motors and smaller generators shifted to the global VPI method in the
early 1970s. The hybrid epoxy VPI resin used for turbine generators was optimized for the previously
 82

developed processing equipment and insulation requirements. It is comprised of a modified epoxy

resin, prepared in a resin cooker to create polyester linkages, and is compatible with styrene for
viscosity control. The final resin cure was achieved by cross-linking through the epoxy or oxirane
group.
After Siemens acquired Westinghouse in the late 1990s, the Thermalastic system underwent
many refinements in materials and processing while maintaining the same resin system. Now a days
there are not much changes though.

17.General Electric Co. :Micapals I and II™, Epoxy Mica Mat™,

Micapal HT™, and hydromat™

It was introduced to the industry in an IEEE Technical paper in 1958, after several years of
limited production. Micapal 1 contained approximately 50% GE Micamat™ (paper), made with
calcined muscovite, and 50% muscovite splitting.
winding operation.
After a 12-year development program, General Electric announced the MICAPAL II™ insulation for
large turbine generator stator windings in 1978. This solvent less, resin-rich, second-generation epoxy
mica paper insulation system has been used on most large steam turbine generators since that time.
In 1999, GE began to offer a reduced-build strand-and-turn insulation, using similar metal
oxide fillers in the large-motor business. These machines use the global epoxy VPI process to make
the glass-fabric-supported Mica-mat insulation systems for machines at least up to 13.8 kV ratings.
Several generations of VPI resins have been used by GE for motor manufacture. Two of these epoxy
resin systems have been based on controlled reactivity chemistry. The most recent improvement
creates polyether linkages in cured Di-Glycidyl ether Bis-Phenol, an epoxy resin provides high
reactivity at curing temperatures with excellent shelf life at room temperature.

18.Alsthom, GEC Alsthom, Alstom Power: Isotenax™, Resitherm™, Resiflex™,

Resivac™, and Duritenax™
During the 1950s, Alsthom licensed the resin technology used in the GE Micapal I system to create
the first Isotenax™ system. There were several differences in materials and processes between the
two systems. Isotenex used only mica paper, not mica splittings. The resin-rich impregnating epoxy
contained significant amounts of a solvent mixture that had to be removed after the glass-backed mica
paper tape was wrapped around the stator bars. Since the 1980s the UK operations of Alsthom have
also worked with global VPI processing and an insulation system called Resivac™. Recent advances
in the VPI system have used bisphenol epoxy resins with a latent Lewis acid catalyst system
 83

19. Siemens AG, KWU: Micalastic™

Siemens began using the individual-bar VPI process with polyester resins and mica splittings as early
as 1957 for hydro and steam turbine generators, with initial help from Westinghouse. This system was
trade named Micalastic. Production continued with this combination of resins and processes for at
least 10 years. Except for indirect cooled generators and direct-cooled generators rated at more than
about 300 MVA or so, which still use the individual bar epoxy VPI methods, the global VPI process
has been standard for all motor and turbo generator stators since 1986. For its large global VPI
stators, this manufacturer avoids difficulties due to shear stress at the interface of the bar to the stator
core by employing a slip plane. The slip plane consists of mica splitting sandwiched between two
semi conductive tapes.

20.ABB Industrie AG: Micadur™, Micadur Compact™, Micapact™

and Micarex™
Brown Boveri AG started changing from resin-rich asphalt mica flake ground-wall insulation about
1953, first using modified polyester resins and then switching to epoxy resins to make resin-rich
tapes. The ABB Group name for bars and coils manufactured from the epoxy resin-rich system is
Micarex™. Initially, these tapes were applied by hand and later by machine taping, followed by hot-
press consolidation and curing. New machine production with this system will stop with the end of
turbo generator production in Sweden, although some repair licensees will continue using Micarex
for some time.
The Micadur™ insulation system was introduced in 1955 by Brown Boveri as an individual
bar VPI method before the merger of ASEA with Brown Boveri to form ABB in the mid 1980s,
ASEA also developed the technology for individual bar VPI production, using similar materials. The
result was Micapact™, introduced in 1962 for the stator insulation of large rotating machines. It was
made with glass-backed mica paper, impregnated with a special mixture of an epoxy resin, curing
agent, and additives. Unlike most other VPI tapes, the glass backing and mica paper lack any
impregnant or bonding resin. The adhesion between mica paper and glass was accomplished by an
extremely thin layer of material, which was melted at a high temperature during formation of the
tape. The tape did not contain any volatile matter, which means that the completed machine taped bar
insulation was more easily evacuated and impregnated.

15.6 Toshiba Corporation: Tosrich™ and Tostight- I™

The Toshiba Tosrich™ insulation system for low-voltage, small-capacity generators with a relatively
small number of insulation layers was based on a resin-rich mica paper tape. The solvent containing
 84

synthetic resin was impregnated into the mica tape, wound onto a coil and cured in a mold. Although
used successfully for many years for smaller machines, its replacement with a solvent less epoxy,
resin-rich mica paper tape during the 1990s allowed the improved Tosrich to be applied to medium-
capacity generators; it is still gaining manufacturing and service experience.
For larger machines, the Tostight-I™ insulation system was developed.A new generation of the
Tostight-I VPI insulation system was introduced in 1998. It has been optimized to improve heat
resistance and to be environmentally friendly in materials, equipment, production methods, and
disposal of waste. The mica paper has been changed to replace the aramid fibrids with short glass
fibers. The new impregnating resin is principally a high-purity, heat-resistant epoxy resin, employing
a complex molecular capsule, latent hardening catalyst that is activated by heat to quickly cure and
produce a high-heat-resistant, mechanically and electrically strong filling material for the mica. The
revised system is manufactured using new production equipment, including a fully automatic taping
machine and a new vacuum pressure impregnation facility and curing oven. The VPI tank is equipped
to control vacuum and impregnation as a parameter of the coil capacitance. The new Tostight-I is
intended to be usable for all types of medium and large generators.

21. Mitsubishi Electric Corporation

The ground-wall insulation systems employed by Mitsubishi until the 1990s were largely
based on licenses obtained from Westinghouse. During the late 1990s, Mitsubishi introduced a new
global VPI insulation system for air-cooled generators up to 250 MVA. The new system
supplemented an older global VPI system, used for air-cooled generators of up to 50 MVA rating. The
new system uses a glass-fabric-backed mica paper tape, bonded with a very small amount of
hardener-free epoxy resin as an adhesive. The global VPI resin is an epoxy anhydride.

22. Hitachi, Ltd.: Hi-Resin™, Hi-Mold™, and Super Hi-Resin™

Hitachi also introduced a pre impregnated or resin-rich mica paper insulation, called the Hi-
Mold™ coil in 1971 This press-cured system uses an epoxy resin to impregnate glass-cloth-backed
mica paper, which is partially cured to the B stage. The high-performance resin was selected to obtain
superior electric and thermal characteristics for use in machines rated for up to Class F insulation
performance. The Hi-Mold system is used for hydro and gas turbine peaking generators and for heavy
duty or other unfavorable environments in synchronous and induction motors.
23.Summary of Present-Day Insulation Systems:
A review of subsections 4.2.1 through 4.2.8 shows that all of the world’s larger OEMs are
currently using various mixtures and types of epoxy resins and mica paper to make their stator coil
ground-wall insulation systems. The compositions are adjusted or tailored to accommodate the exact
process used in their manufacture. The end results are comparable in terms of inherent insulation
 85

quality as related to the machine and insulation design parameters, provided that consistent quality
control practices are routinely carried out. This fact is recognized by some large suppliers of rotating
machines, who will, in times of extraordinary demand, out-source or purchase generators to their own
design from competitors, while allowing the supplier to use their own insulation systems. We
presented here the most efficient and reliable system of insulation, the Micalastic insulation

• A NEW FLUSH IN INSULATION SYSTEM

1. MICALASTIC
Of all these
insulation processes
the insulation which
was preferred by
ITAIPU power plant
was the
MICALASTIC the
features of which
will be briefed
below:
“As central
components of
hydroelectric power
plants, generators are
subjected to
operating stresses
which influence the
long-term
performance of the
winding insulation.
B19 Rotor of the worlds largest hydro generator ITAIPU at the assembly

Failure of the insulation can lead to lengthy downtimes. The un surpassed reliability of products such
as MICALASTIC® insulation is therefore of great economic significance.”
The capacity of a hydroelectric power plant is determined by the available water flow and
head. Both of these parameters vary widely, and generators can be dimensioned for any rating
between 10 kW and 800 MW. The head determines the turbine type as well as the speed, which can
 86

lie between 50 and 1500 rpm. Additional parameters include the generator voltage, the rotor’ s
moment of inertia, the runaway speed of the turbine, the physical design of the generator (horizontal
or vertical) and various requirements imposed by the grid. Hydroelectric generators are therefore
always custom designed. Dimensions and weights can assume enormous proportions External
diameters of up to nearly 23 meters are possible, and total weight can amount to as much as 3500
metric tons. Generators of this size cannot be assembled and tested at the factory. Nevertheless, the
generators can be expected to operate well right after their initial installation at the power plant. It
was once correctly stated that” the construction of a hydroelectric generator can be compared to
making a tailor made suit without trying it on”.

To date, Siemens has manufactured more than 1200 large hydroelectric generators with a combined
capacity in excess of 80,000 MVA. Of these, 360 generators (over 50,000 MVA) have MICALASTIC
windings. These machines are characterized by their outstanding reliability, which can be attributed in
large measure to their high quality MICALASTIC insulation system.

2. The MICALASTIC Insulation in ITAIPU™

MICALASTIC is the registered trademark for Siemens insulation systems for high-voltage windings
of rotating electrical machines. These systems use mica, a material capable of withstanding high
electrical and thermal loads, together with curable, elastic epoxy resins as bonding material. Since the
early days of electrical machine construction, the naturally occurring, inorganic mineral mica has
been an indispensable constituent of high voltage insulation systems. The most important criterion for
the use of mica is its ability to durably withstand the partial electrical discharges which can occur
inside the insulation due to high electrical stresses.

16.2.1 Manufacturing and Design

As early as 1957, Siemens-Dynamo werk in Berlin manufactured the first stator windings that made
use of mica tape and a vacuum-pressure impregnation process. With this method, single coils and
Roebel bars for hydroelectric generators are continuously wrapped with mica tape in the slot and end
sections. The taped winding elements are then dried out and degassed in a vacuum impregnation tank,
and flooded with low-viscosity, curable synthetic resin. High nitrogen pressure applied to the
impregnating bath completely impregnates the mica tape. After being placed in accurately sized,
portable pressing molds, the insulation is cured at high temperatures in large chamber ovens.
Continued development of this insulation technology ultimately led to the use of a film of ground
mica on mechanically strong glass fabric as the carrier material with epoxy resin as the impregnant,
which produced a very durable electrically, thermally and mechanically),modern insulation system.
 87

Long duration tests in a slot model were unnecessary, since the desired voltage endurance had already
been achieved in the previous development stages (Fig. 2) using lower-quality carrier materials.
Short-duration tests were performed, however, for verification.
16.2.2 Fitting of Roebel Bars into Slots:
Winding elements with cured MICALASTIC insulation are secured in the slots by filling up the
tolerances between the slot wall and the conductive surface (coil side corona shielding) of the bar
insulation. Initially, Siemens used graphite-treated paper as filler material. Since about 1969, however
a special bar fitting procedure has been used for hydroelectric generators. The main features of this
procedure are U-shaped slot liners made of polyester fleece impregnated with a conductive material,
and a conductive, curable synthetic resin paste between the surface of the bar insulation and the slot
liner (Fig. 3). Therefore, the insulation does not stick to the stator core, and the option of removing
the bars, even though seldom required, is retained. In the radial direction, the slot portion of the
winding elements is secured by means of various packing strips or ripple springs, and slot wedges.
Bracing the end windings and jumpers by using glass fiber reinforced spacers and epoxy-resin
impregnated cording makes the winding resistant to electro dynamic forces during operation and to
possible short-circuit faults. This resistance is also aided considerably by the mechanical stiffness of
the MICALASTIC insulation, which is also cured within the end winding.

16.2.3 Thermal Stability

The MICALASTIC insulation system was developed strictly for a continuous load in accordance
with temperature class F (155°C). Nevertheless, generator design engineers generally guarantee
compliance with class B (130°C) temperature limits for nominal operating conditions, as is also
required in most invitations to tender. In practice, the stator windings of hydroelectric generators are
frequently dimensioned for even lower operating temperatures, because the stators will usually be
optimized for good efficiency by adding electrically active material (winding copper and core
lamination). Particularly low operating temperatures can be expected in the case of stator windings
with direct water cooling. With an appropriately dimensioned de mineralized-water cooling system,
the maximum winding temperature can be reduced to 70°C and lower. Thermal aging of the
insulation is therefore essentially eliminated, and thermo mechanical stresses are also substantially
reduced. The resulting increase in operational reliability makes a real difference in the case of
hydroelectric generators which are essential to safe grid operation
 88

17. CONCLUSION:

Hence Vacuum-Pressure Impregnation technology can be used in a wide range of applications from
insulating electrical coil windings to sealing porous metal castings. It normally produces better work
in less time and at a lower cost than other available procedures.

Our VPI systems can be configured in a variety of ways, depending on the size and form of the
product to be impregnated, the type of impregnant used and other production factors. System
packages include all necessary valves, gauges, instruments and piping. These systems can be large or
small, simple or highly sophisticated and equipped with manual, semi-automatic or automatic
controls.

Vacuum Pressure Impregnation (VPI) yields superior results with better insulating properties,
combined with “flexible” rigidity, resulting in greater overall reliability and longer life. VPI reduces
coil vibration by serving as an adhesive between coil wires, coil insulation, and by bonding coils to
their slots.

18 Bibliography

##############################Abbey eeeeedddde see

pictures of ABB n bhel pics ,also tabular forms to venky show, complete graphs ,roebel shit of
venky!!