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- Herausgeber: John Wiley & Sons
- Kategorie: Wissenschaft und neue Technologien
- Serie: IEEE Press Series on Power Engineering
- Sprache: Englisch
A fully expanded new edition documenting the significant improvements that have been made to the tests and monitors of electrical insulation systems Electrical Insulation for Rotating Machines: Design, Evaluation, Aging, Testing, and Repair, Second Edition covers all aspects in the design, deterioration, testing, and repair of the electrical insulation used in motors and generators of all ratings greater than fractional horsepower size. It discusses both rotor and stator windings; gives a historical overview of machine insulation design; and describes the materials and manufacturing methods of the rotor and stator winding insulation systems in current use (while covering systems made over fifty years ago). It covers how to select the insulation systems for use in new machines, and explains over thirty different rotor and stator winding failure processes, including the methods to repair, or least slow down, each process. Finally, it reviews the theoretical basis, practical application, and interpretation of forty different tests and monitors that are used to assess winding insulation condition, thereby helping machine users avoid unnecessary machine failures and reduce maintenance costs. Electrical Insulation for Rotating Machines: * Documents the large array of machine electrical failure mechanisms, repair methods, and test techniques that are currently available * Educates owners of machines as well as repair shops on the different failure processes and shows them how to fix or otherwise ameliorate them * Offers chapters on testing, monitoring, and maintenance strategies that assist in educating machine users and repair shops on the tests needed for specific situations and how to minimize motor and generator maintenance costs * Captures the state of both the present and past "art" in rotating machine insulation system design and manufacture, which helps designers learn from the knowledge acquired by previous generations An ideal read for researchers, developers, and manufacturers of electrical insulating materials for machines, Electrical Insulation for Rotating Machines will also benefit designers of motors and generators who must select and apply electrical insulation in machines.
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Veröffentlichungsjahr: 2014
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Table of Contents
Cover
Series
Title Page
Copyright
Preface
Chapter 1: Rotating Machine Insulation Systems
1.1 Types of Rotating Machines
1.2 Winding Components
1.3 Types of Stator Winding Construction
1.4 Form-Wound Stator Winding Insulation System Features
1.5 Random-Wound Stator Winding Insulation System Features
1.6 Rotor Winding Insulation System Components
References
Chapter 2: Evaluating Insulation Materials and Systems
2.1 Aging Stresses
2.2 Principles of Accelerated Aging Tests
2.3 Thermal Endurance Tests
2.4 Electrical Endurance Tests
2.5 Thermal Cycling Tests
2.6 Nuclear Environmental Qualification Tests
2.7 Multifactor Stress Testing
2.8 Material Property Tests
References
Chapter 3: Historical Development of Insulation Materials and Systems
3.1 Natural Materials for Form-Wound Stator Coils
3.2 Early Synthetics for Form-Wound Stator Coils
3.3 Plastic Films and Non-Wovens
3.4 Liquid Synthetic Resins
3.5 MICA
3.6 Glass Fibers
3.7 Laminates
3.8 Evolution of Wire and Strand Insulations
3.9 Manufacture of Random-Wound Stator Coils
3.10 Manufacture of Form-Wound Coils and Bars
3.11 Wire Transposition Insulation
3.12 Methods of Taping Stator Groundwall Insulation
3.13 Insulating Liners, Separators, and Sleeving
References
Chapter 4: Stator Winding Insulation Systems in Current Use
4.1 Consolidation of Major Manufacturers
4.2 Description of Major Trademarked Form-Wound Stator Insulation Systems
4.3 Recent Developments for Form-Wound Insulation Systems
4.4 Random-Wound Stator Insulation Systems
References
Chapter 5: Rotor Winding Insulation Systems
5.1 Rotor Slot and Turn Insulation
5.2 Collector Insulation
5.3 End Winding Insulation and Blocking
5.4 Retaining Ring Insulation
5.5 Direct-Cooled Rotor Insulation
5.6 Wound Rotors
5.7 Superconducting Sychronous Rotors
References
Chapter 6: Rotor and Stator Laminated Cores
6.1 Magnetic Materials
6.2 Mill-Applied Insulation
6.3 Lamination Punching and Laser Cutting
6.4 Annealing and Burr Removal
6.5 Enameling or Film Coatings
6.6 Stator and Rotor Core Construction
References
Chapter 7: General Principles of Winding Failure, Repair and Rewinding
7.1 Failure Processes
7.2 Factors Affecting Repair Decisions
7.3 Rapid Repair of Localized Stator Winding Damage
7.4 Cutting out Stator Coils After Failure
7.5 Bar/Coil Replacement and Half Coil Splice
7.6 Rewinding
References
Chapter 8: Stator Failure Mechanisms and Repair
8.1 Thermal Deterioration
8.2 Thermal Cycling
8.3 Inadequate Resin Impregnation or Dipping
8.4 Loose Coils in the Slot
8.5 Semiconductive Coating Failure
8.6 Semiconductive/Grading Coating Overlap Failure
8.7 High Intensity Slot Discharge
8.8 Vibration Sparking (Spark Erosion)
8.9 Transient Voltage Surges
8.10 Repetitive Voltage Surges Due to Drives
8.11 Contamination (Electrical Tracking)
8.12 Abrasive Particles
8.13 Chemical Attack
8.14 Inadequate End Winding Spacing
8.15 End Winding Vibration
8.16 Stator Coolant Water Leaks
8.17 Poor Electrical Connections
References
Chapter 9: Round Rotor Winding Failure Mechanisms and Repair
9.1 Thermal Deterioration
9.2 Thermal Cycling
9.3 Abrasion Due to Imbalance or Turning Gear Operation (Copper Dusting)
9.4 Pollution (Tracking)
9.5 Repetitive Voltage Surges
9.6 Centrifugal Force
9.7 Operating without Field Current
9.8 Remedies
References
Chapter 10: Salient Pole Rotor Winding Failure Mechanisms and Repair
10.1 Thermal Deterioration
10.2 Thermal Cycling
10.3 Pollution (Tracking and Moisture Absorption)
10.4 Abrasive Particles
10.5 Centrifugal Force
10.6 Repetitive Voltage Surges
10.7 Salient Pole Repair
References
Chapter 11: Wound Rotor Winding Failure Mechanisms and Repair
11.1 Voltage Surges
11.2 Unbalanced Stator Voltages
11.3 High Resistance Connections-Bar Lap and Wave Windings
11.4 End Winding Banding Failures
11.5 Slip Ring Insulation Shorting and Grounding
11.6 Wound Rotor Winding Repair
References
Chapter 12: Squirrel Cage Induction Rotor Winding Failure Mechanisms and Repair
12.1 Thermal
12.2 Cyclic Mechanical Stressing
12.3 Poor Design/Manufacture
12.4 Repairs
References
Chapter 13: Core Lamination Insulation Failure and Repair
13.1 Thermal Deterioration
13.2 Electrical Degradation
13.3 Mechanical Degradation
13.4 Failures Due to Manufacturing Defects
13.5 Core Repairs
References
Chapter 14: General Principles of Testing and Monitoring
14.1 Purpose of Testing and Monitoring
14.2 Off-Line Testing Versus On-Line Monitoring
14.3 Role of Visual Inspections
14.4 Expert Systems to Convert Data into Information
References
Chapter 15: Off-Line Rotor and Stator Winding Tests
15.2 DC Hipot Test
15.3 Polarization/Depolarization Current (PDC)
15.4 DC Conductivity
15.5 Poor Connection Hot Spot (High Current-Infrared Camera)
15.6 AC Hipot
15.7 Capacitance
15.8 Stator Capacitance Tip-Up
15.9 Capacitive Impedance Test for Motor Stators
15.10 Dissipation (or Power) Factor
15.11 Power (Dissipation) Factor Tip-Up
15.12 Off-Line Partial Discharge for Conventional Windings
15.13 Off-Line Partial Discharge for Inverter-Fed Windings
15.14 Stator Blackout and Ultraviolet Imaging
15.15 Stator Partial Discharge Probe
15.16 Stator Surge Voltage
15.17 Inductive Impedance
15.18 Semiconductive Coating Contact Resistance
15.19 Conductor Coolant Tube Resistance
15.20 Stator Wedge Tap
15.21 Slot Side Clearance
15.22 Stator Slot Radial Clearance
15.23 Stator End Winding Bump
15.24 Stator Pressure and Vacuum Decay
15.25 Rotor Pole Drop (Voltage Drop)
15.26 Rotor RSO and Surge
15.27 Rotor Growler
15.28 Rotor Fluorescent Dye Penetrant
15.29 Rotor Rated Flux
15.30 Rotor Single-Phase Rotation
References
Chapter 16: In-Service Monitoring of Stator and Rotor Windings
16.1 Thermal Monitoring
16.2 Condition Monitors and Tagging Compounds
16.3 Ozone
16.4 Online Partial Discharge Monitor
16.5 Online Capacitance and Dissipation Factor
16.6 Endwinding Vibration Monitor
16.7 Synchronous Rotor Flux Monitor
16.8 Current Signature Analysis
16.9 Bearing Vibration Monitor
16.10 Stator Winding Water Leak Monitoring
References
Chapter 17: Core Testing
17.1 Knife
17.2 Rated Flux
17.3 Core Loss
17.4 Low Core Flux (El-CID)
References
Chapter 18: New Machine Winding and Rewind Specifications
18.1 Objective of Stator and Rotor Winding Specifications
18.2 Trade-Offs Between Detailed and General Specifications
18.3 General Items for Specifications
18.4 Technical Requirements for New Stator Windings
18.5 Technical Requirements for Insulated Rotor Windings
References
Chapter 19: Acceptance and Site Testing of New Windings
19.1 Stator Winding Insulation System Prequalification Tests
19.2 Stator Winding Insulation System Factory and On-Site Tests
19.3 Factory and On-Site Tests for Rotor Windings
19.4 Core Insulation Factory and On-Site Tests
References
Chapter 20: Maintenance Strategies
20.1 Maintenance and Inspection Options
20.2 Maintenance Strategies for Various Machine Types and Applications
Reference
Appendix A
A.1 Insulation Material Tables
Appendix B
B.1 Insulation System Tables
Index
Series
End User License Agreement
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Guide
Table of Contents
List of Illustrations
Figure 1.1
Figure 1.2
Figure 1.3
Figure 1.4
Figure 1.5
Figure 1.6
Figure 1.7
Figure 1.8
Figure 1.9
Figure 1.10
Figure 1.11
Figure 1.12
Figure 1.13
Figure 1.14
Figure 1.15
Figure 1.16
Figure 1.17
Figure 1.18
Figure 1.19
Figure 1.20
Figure 1.21
Figure 1.22
Figure 1.23
Figure 1.24
Figure 1.25
Figure 2.1
Figure 2.2
Figure 2.3
Figure 3.1
Figure 4.1
Figure 6.1
Figure 6.2
Figure 6.3
Figure 6.4
Figure 6.5
Figure 7.1
Figure 7.2
Figure 8.1
Figure 8.2
Figure 8.3
Figure 8.4
Figure 8.5
Figure 8.6
Figure 8.7
Figure 8.8
Figure 8.9
Figure 8.10
Figure 8.11
Figure 8.12
Figure 8.13
Figure 8.14
Figure 8.15
Figure 8.16
Figure 8.17
Figure 8.18
Figure 8.19
Figure 8.20
Figure 8.21
Figure 9.1
Figure 9.2
Figure 9.3
Figure 9.4
Figure 10.1
Figure 10.2
Figure 10.3
Figure 10.4
Figure 10.5
Figure 11.1
Figure 11.2
Figure 11.3
Figure 12.1
Figure 12.2
Figure 12.3
Figure 12.4
Figure 12.5
Figure 12.6
Figure 12.7
Figure 12.8
Figure 12.9
Figure 13.1
Figure 13.2
Figure 13.3
Figure 13.4
Figure 13.5
Figure 13.6
Figure 13.7
Figure 13.8
Figure 13.9
Figure 13.10
Figure 13.11
Figure 13.12
Figure 15.1
Figure 15.2
Figure 15.3
Figure 15.4
Figure 15.5
Figure 15.6
Figure 15.7
Figure 15.8
Figure 15.9
Figure 15.11
Figure 16.1
Figure 16.2
Figure 16.3
Figure 16.4
Figure 16.5
Figure 16.6
Figure 16.7
Figure 16.8
Figure 16.9
Figure 16.10
Figure 16.11
Figure 16.12
Figure 16.13
Figure 16.14
Figure 16.15
Figure 16.16
Figure 16.17
Figure 16.18
Figure 16.19
Figure 16.20
Figure 17.1
Figure 17.2
Figure 17.3
Figure 17.4
Figure 17.5
Figure 17.6
Figure 17.7
Figure 17.8
Figure 17.9
Figure 17.10
Figure 17.11
Figure 17.12
Figure 17.13
Figure 17.14
Figure 17.15
Figure 17.16
Figure 17.17
Figure 17.18
Figure 17.19
Figure 17.20
Figure 17.21
Figure 18.1
Figure 18.2
Figure 18.3
Figure 18.4
Figure 18.5
Figure 18.6
Figure 18.7
Figure 18.8
Figure 18.9
Figure 18.10
Figure 18.11
Figure 18.12
List of Tables
Table 2.1
Table 2.2
Table 2.3
Table 2.4
Table 6.1
Table 7.1
Table 15.1
Table 15.2
Table 15.3
Table 15.4
Table 16.1
Table 16.2
Electrical Insulation for Rotating Machines
Design, Evaluation, Aging, Testing, and Repair
Second Edition
Greg Stone
Ian Culbert
Edward A. Boulter
Hussein Dhirani
Copyright © 2014 by The Institute of Electrical and Electronics Engineers, Inc.
Published by John Wiley & Sons, Inc., Hoboken, New Jersey. All rights reserved
Published simultaneously in Canada
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Library of Congress Cataloging-in-Publication Data is available.
Electrical insulation for rotating machines : design, evaluation, aging, testing, and repair / Greg C. Stone, Ian Culbert, Edward A. Boulter, Hussein Dhirani. – Second edition.
pages cm
Includes bibliographical references and index.
ISBN 978-1-118-05706-3 (cloth : alk. paper) 1. Electric insulators and insulation. 2. Electric machinery–Windings. 3. Electric motors. 4. Electric machinery–Protection. I. Stone, Greg C., editor. II. Culbert, Ian, editor. III. Boulter, Edward A., editor. IV. Dhirani, Hussein, editor.
TK3401.E424 2014
621.31′042–dc23
2014021677
Preface
This edition was updated by two of us, Greg Stone and Ian Culbert. Given the developments in rotating machine insulation in the past decade, readers will see expanded information on the effect of drives on insulation, the addition of a number of relatively new failure mechanisms, and new diagnostic tests. Many more photos of deteriorated insulation systems have been added in this edition. Many more references have been added, and recent changes in IEEE and IEC standards have been incorporated. We have also added descriptions of the insulation systems used by Chinese and Indian machine manufacturers. The information on Chinese systems came from Mr. Yamin Bai of North China EPRI. Mr. Bai and his colleagues were also responsible for the Chinese version of the first edition of this book. New appendices were added, which give detailed information on the insulation systems used by many manufacturers, as well as insulation material properties. These tables first appeared in a US Electric Power Research Institute (EPRI) document that is long out of print. However, given the number of machines still using these systems and materials, we thought it will be useful to include the information here.
We again would like to thank our spouses, Judy and Anne, and also our employer, Iris Power L.P. We are also grateful to Ms. Resi Zarb for help in organizing and editing the second edition. Finally, we thank the readers of the first edition who took time to point out errors and omissions in the first edition.
Greg Stone and Ian Culbert
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