APPLICATION

Impact of new motor and generator insulation systems

by P Marek, F Senn, W Grubelnik and W Ladsttter, Isovolta Group, Austria The demand for increasing the efficiency of electrical HV machines with regard to overall costs, maintenance costs, service life and power output is high. The reasons are obvious. Higher demand for electricity, increasing raw material costs and increasing maintenance costs are all factors. Erecting new power plants is often not possible, and so other ways to meet the needs are required.

Increasing operating performance and efficiency of an electric machine can be achieved through the improvement or modification of the components of the primary insulating material. Relevant variables in the construction of a machine can be found in the components of the insulating materials and their overall thickness. These components can influence the electric strength and overall service life. In addition, the electrical insulation system determines the thermal classification and therefore the construction of a machine. What are the influencing parameters pertaining to the insulation system in creating a more efficient machine? What parts of the system are we able to modify in a meaningful way? Is it possible to implement one very good material into the system without problems? Will the market accept the new system? In this paper, an attempt is made to answer these questions. Some examples are given to show the influence of one particular product development regarding power output and savings. Efficiency and cost are two major keywords in the field of electrical machines, especially in terms of generators. Can they be influenced by the insulation system? The insulating system in electrical machines is one of the main features and is jointly responsible for the historical development of power output of rotating electrical machines. Continuous improvemenrts have been achieved over time. In the beginning, natural products such as silk, wool, cellulose and flax together with natural varnishes and petroleum derivatives were used for insulation. Due to optimization, these materials were displaced or materials like asbestos, quartz or other minerals have been added [1], [2]. Mica was introduced into the insulation of high voltage electrical machines because of its outstanding mechanical and electrical properties. The greatest historical step forward was made in the middle of the last century when mica paper in combination with artificial epoxy resin or polyester resin, and with a glass cloth as a carrier, was introduced as the main insulation of high voltage machines. Fig. 1 shows some major steps regarding development of electrical machines. Materials used for electrical insulation systems and possible future enhancements A state-of-the-art insulation system for rotating high voltage machines consists of impregnation resin and mica tape that is built out of mica, binder resin and a carrier (glass cloth, PET film or PT fleece) Impregnation resin There are different impregnation resins available for HV machines, such as epoxy-anhydride, epoxy-polyester, polyester and polyimid resins. For all kinds of resins, filling with special materials to increase the

thermal and mechanical performance is possible, and nano particles as fillers are under investigation. Binder resin Binder resins can also be filled, but the potential improvements do not seem to be to be very high because of the low amount on binder resin in the tapes. Mica paper The performance of mica paper can be influenced in several ways. There is the particle size of the mica itself, and the structure of the mica paper that is influenced if you use calcined or uncalcined mica. The mica source and the impregnability influence the compactness of the mica paper. To increase the mechanical performance of the mica paper, aramide fibres are introduces, which is state-of-the-art. Filling with metallic components to increase the thermal conductivity has also been done successfully. Glass cloth There are different ways to influence the performance of the glass cloth used in mica tapes. You can vary the numbers and thickness of the yarns used for the glass cloth. This will directly influence the mechanical

Fig. 1: Historical overview

Fig. 2: Thickness difference between standard and Powerfab

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features of the glass cloth and later on, the mica tape. The structure of the yarns is also related to the mechanical behaviour. Drilled yarns and a newly developed parallel yarn are used for mica tapes. The big influence on the thermal performance is related to the finish used on the yarns. The potential for improvements of the glass cloth are an increase of the thermal transmission, and improvements in the mechanical features New glass cloth carrier for mica tapes Isovolta has focused on influencing the performance of the insulation system by using a new glass cloth. This glass cloth is called Powerfab. Powerfab is a new type of glass cloth used as a carrier for high voltage insulation materials in resin rich (Calmicafab) and VPI technology (Porofab). The glass cloth used for this technology is thinner compared to the glass cloth currently used, although the total weight is the same. The reason for this comes out of a new production method for glass cloths. The glass filaments are not twisted any more, but instead they are just laid in parallel as shown in Fig. 2 Every single filament is covered with a finish. Due to the parallel filaments, the crossing sections of the warp and weft yarns are much smaller and prevent voids being created in this critical area during the VPI process and the pressing process when using resin rich technology (Fig. 3). Measurements and results All tests on the the mechanical, electrical and thermal properties are done with VPI tapes based on an epoxy anhydride system, and are done in accordance to the IEC standards relevant to the subject. Mechanical properties
Fig. 3: Contact area for the binder resin

The mechanical properties were taken from the tape itself, as well as from the VPIed and cured mainwall insulation. Thickness The main goal of our studies was to reduce the thickness of the tape, and of course, the total thickness of the main wall insulation. Fig. 4 shows the thickness reduction of the VPI tape. The average value of the standard material is about 0,142 mm; the value for the Porofab tape is about 0,124 mm. This leads to a reduction of the thickness of about 14,5 %. Fig. 5 shows the thickness situation for the VPIed and cured main wall insulation for different grades of VPI tapes. It is seen that with the Porofab technology an increase of approx. 15% of the total thickness is achieved. All other mechanical properties such as tensile strength, flexural strength and tear edge strength show the same values. In most cases, higher values are achieved compared to the standard tape [6]. Electrical properties Breakdown voltage To be able to verify the results of the breakdown voltage measurements, the same number of layers were taped on the test bars. This leads to the same amount of mica in the insulation and so the values can be compared to one another. Due to the thinner Porofab material, the total thickness of the insulation taped with Porofab is about 15% thinner. Fig. 6 shows the results of the breakdown voltage test. The absolute values are related to 1 mm of main wall thickness in this case, so that it is possible to compare the two different main wall built-ups directly. The test is conducted in accordance with the IEC 60243 standard. Life endurance To perform the life endurance test, the same sample conditions as above (breakdown voltage) were taken to get comparable results. The test was done at 155C. An electrical stress of 12,0 kV/mm for the reference system and an electrical stress of 14,6 kV/mm for the Porofab system was applied. Fig. 7 shows the result as a Weibull distribution. [5]. The 63% values of the Porofab insulation (violet dots), are much higher compared to the standard material (blue dots). energize - November 2007 - Page 52

Fig 4: Thickness comparison a standard 0,14 tape and Porofab

Fig. 5: Insulation thickness for 10 kV coils

Fig. 6: Measurement of breakdown voltage.

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All these outstanding results can be explained with reference to Fig. 8 and 9. The pictures show a sectrion through the already impregnated and cured insulation. Fig. 8 was taken using the standard insulation. Clearly seen is the significant area were only the resin is located. In these areas there is no barrier against partial discharge attack, and the resin will be destroyed within a very short time. Bonding forces are also low in these areas. Compared to Fig. 8 which shows the standard insulation, Fig. 9 shows the section through the Porofab insulation. It is seen that there are no significant areas without mica or glass. Partial discharge attack is blocked by mica everywhere. The resin content for the Porofab insulation is lower compared to the standard insulation. Thermal properties Due to the reduction of resin inside the insulation, the thermal properties of the insulation are significantly improved.

Fig. 7: Weibull distribution of life endurance

Fig. 10: Output power due to increased thermal conductivity

Fig. 10 shows the influence of the temperature and the thermal conductivity, together with an increase of the field strength on the power output of the machine. Thermal conductivity Increasing the thermal conductivity by adding metallic fillers into the mica tapes is already known, and is performed by one of the major mica tape suppliers. The value reached is approx. 0,52 W/mK. The disadvantage of this technology is the reduced mica content compared to the standard tapes [3, 4].
Fig. 8: REM picture of the standard insulation

The other possibility to increase thermal conductivity is to reduce the total main wall thickness. Of course, the main goal for this option is to keep the same mechanical, thermal and electrical properties as the comparable standard insulation thickness. Seen from the results above, this is achieved with the Powerfab technology. The value for the Porofab insulation system impregnated in epoxy anhydrite resin and taken from the samples produced for the voltage endurance test was taken from three independent measurements, and 0,37 W/mK is the average value of these measurements. To achieve the same thermal conductivity as for example a 2 mm main wall thickness with metallic filled tape, the Porofab tape insulation can be about 1,46 mm thick (Fig. 11). Thermal transmission coefficient However, significantly more interesting is the thermal transmission coefficient. It defines the capability of the copper losses to penetrate through the insulation towards the iron core. The higher the thermal transmission coefficient, the lower the copper temperature in service. The calculation of the thermal transmission coefficient is shown in Equation 1.

Fig. 9: REM picture of the Porofab insulation

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Power output changes (1) where A T s P = cross section = temperature difference = thermal conductivity = thickness of insulation = Power, heat transmission Insulation material in generators For a stator up to 28 kV, several materials are needed, like ground wall insulation, corona protection, varnishes, resins and some supporting materials. For a rotor that is lower than 1 kV, papers and Nomex is used together with some supporting materials. In the housing, varnishes and supporting materials are used. The costs of the stator insulation material are about 1 5 % of the total generator costs. From this percentage it is clear that there will not be big changes in the total costs if these material costs change. However, the performance of the insulating material can significantly influence the total design and thus the total costs. The following examples should illustrate this. Hydro power generator An existing synchronous generator with the technical data shown in Table 1 is used for the calculation of the possible power output increase using the Porofab tape instead of a standard tape.

SN = 32 MVA cosN = 0,85

UN = 10500 V PN = 27,2 MW

IN = 1760 A fN = 50 Hz

Table 1: Technical data of the generator

The calculation is based on the requirement for the copper temperaturenot to exceed 100C. Due to having existing slot dimensions and the use of thinner main wall insulation, the copper cross section has to be increased. The increased factor is calculated as: Anew = Aold * 1,125 i.e. an increase of 12,5%. For the calculation, A can be seen as a constant. From Equation 1 it is seen that a better thermal conductivity and a thinner insulation thickness directly results in a better thermal transmission cofficient. Fig. 12 shows the thermal conductivity and the thermal transmission coefficient values for the Porofab material in comparison with the standard material [6]. Both values are significantly increased by the Porofab system. Most impressive is the 75% increase of the thermal transmission coefficient. This is caused by the thinner insulation thickness needed for the Porofab system together with very good thermal conductivity values. For the calculation, the electrical field strength was changed from EN=2,24 kV/mm to EN=3,0 kV/mm. The thermal conductivity was changed from = 0,27 W/mK to = 0,37 W/mK. The difference in power output when using the new Porofab insulation system, compared to the standard system, at the same copper temperature of 100 C is about 16,5 % or SN= 5,3 MVA [7]. Power increase of a large indirect hydrogen cooled turbo generator The power incerease for an existing large turbo generator with details shown in Table 2 was calculated.

Fig. 11: Comparison of the insulation thickness to reach equal thermal conductivity

SN = 440 MVA cosN = 0,80

UN = 20 000 V PN = 352 MW

IN = 12702 A fN = 50 Hz

Table 2: Technical data of the generator

Due to having existing slot dimensions and the use of thinner main wall insulation, the copper cross section has to be increased. The increased factor is calculated as: Anew = Aold * 1,095 i.e. an increase of 9,5%.
Fig. 12: Comparison of thermal properties

This very good value of thermal transmission coefficient can significantly influence the power output of a generator. The following example shall illustrates this further.

For the calculation, the electrical field strength was changed from EN=2,7 kV/mm to EN=3,5 kV/mm. The thermal conductivity was changed from = 0,27 W/mK to = 0,37 W/mK. The difference in power output when using the new Porofab insulation system compared to the standard system, at the same copper temperature is about 20% or SN= 90 MVA.

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Savings of hydro and turbo generators Reduction in production costs With this new development, a design change from water cooled to air cooled turbo generators is possible. This results in following advantages: Simpler generator design No additional equipment and less pipes Less space needed Less connection parts to other systems Simpler construction, less calculating effort Less production time (3 months less) Faster erection
[2]

With reduced slot cross section Reduction of machine dimensions with the same power output (increased power to weight ratio)
[4]

conductivity for turbo generators, Electrical Insulation Conference and Electrical Manufacturing & Coil Winding Technology Conference, 2003. Proceedings, 23-25 Sept. 2003 pp 613 617 R. Brutsch, A. Lutz, G. Liptak, R. Schuler; New high voltage insulation with increased thermal conductivity, Electrical Electronics Insulation Conference and Electrical Manufacturing & Coil Winding Conference, 1993. Proceedings, Chicago 93 EEIC/ICWA Exposition 4-7 Oct. 1993, pp 323 327 P. Marek; Neues Trgersystem fr Hochspannungsisolierungen, Doctor Thesis, TU-Graz, 2006 W. Grubelnik, J. Roberts, B. Koerbler, P. Marek; A New Approach in Insulation Systems for Rotating Machines, EEIC 2005, Indianapolis, Okt. 2005 H. Kfler; Calculation of a hydro generator, TU-Graz, Nov. 2005 W. Ladsttter, Dr. P Marek, W. Grubelnik, . F. Senn; NEW INSULATION TECHNOLOGY IMPACTS GENERATOR DESIGN, PowerGen Conference 2006, Orlando, USA v

Improved heat transfer between conductor and iron core. Tremendous savings can be achieved, especially for large machines where significant design changes for the cooling system can be made. References
[1] E.A. Boulter, G.C. Stone; Historical Development of Rotor and Stator Winding Insulation Materials and Systems, IEEE Electrical Insulation Magazine, May/June 2004, Vol. 20, No. 3, pp. 25-39 G.C. Stone, E.A. Boulter, I. Culbert, H. Dhirani; Electrical Insulation for Rotating Machines, IEEE Press Series on Power Engineering, 2004, pp73 94 M. Tari, K. Yoshida, S. Sekito, J. Allison, R. Brutsch, A. Lutz, N. Frost; A high voltage insulating system with increased thermal

[5]

[6]

Taking all these advantages into consideration, a saving of about 40% of the total costs is achieved. This means US$1,5 to 2-million for a 250 MW generator. Reduction in maintenance and service costs Due to the simpler design, cost reduction during maintenance and service is achieved. The following reasons are responsible for these savings: No hydrogen or water pipes needed Less spare parts Less maintenance work Easier and safer service Efficiency almost the same

[7] [8]

[3]

For the same 250 MW generator, savings of about US$200 000 to 400 000 per year are achieved [8]. Conclusions With reference to the results mentioned above, one can see that the potential of this new technology in the motor and generator business is great. The examples show this clearly. This results from: increasing the specific power output; optimising and saving of raw materials and production costs; operation at lower conductor temperatures; and extending the maintenance intervals. The main feature responsible for this is the reduced main wall insulation thickness, with its great influence of the heat transport from the conductor towards the iron core. A lot of different aspects are influenced by this thickness reduction, such as: With the same slot cross section: Increased conductor cross section (higher current rating, reduced copper losses) Increased number of layers of the main wall insulation (higher mica content, increased electrical life endurance) Influence on the length of the machine energize - November 2007 - Page 55