Insulation Systems for HV Motors

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Insulation systems for HV rotating machines

Insulating systems for HV Motors

HV Motors

Vacuum Pressure Impregnation today: An increasing number of manufacturers and repair shops of high voltage motors are applying the VPI technology in their coil shop. The VPI process is a well established technology and has proven to give a high level of performance and reliability if the insulating materials are selected carefully to fit the type of machine and if they are applied properly. Two main application technologies:

RR Improved testing High costs

Global VPI Hermetic sealing Low costs Not applicable for large machines Difficilt repair

Single bar VPI Improved testing Applicable for large machines High costs

2 | Company Presentation

VPI cycle 1.

Predrying

2.

Dry vacuum

3.

Wet vacuum

4.

Pressure phase

5.

Curing

Materials used for HV motor coils

HV Motors

Many different materials are used for the construction of a high voltage coil or bar: » » » » » » » » »

3 | Company Presentation

Winding wire (A) Conductor insulation (B) Stack consolidation (C) Main wall insulation: Mica tape (D) + VPI resin (H) Conductive paint or tape (F) Stress grading paint or tape (F) Finishing or sealing tapes (E) Bracing materials (G) Slot wedging materials (I)

Conductors and conductor insulation for Coils The preferred conductor insulations for coils used in HV Motors are:
Glass fibers (Silix®)
Daglas®
Austraflex ®
Samicafilm ®

HV Motors

Samicafilm® is a family of Samica/Polyesterfilm conductor tapes with improved binder resin and a special bond coat to enable fast consolidation of the conductor stack. The bond coat is thermo-plastic when pressing and thermo-setting during the cure cycle. Advantages:


a universal conductor tape




can be used with resin-rich or VPI systems




coils can be reshaped and repaired




shorter pressing time




reduces cost of producing coil

Stack consolidation: Hot press 5 min/150°C + cold press 5 min.

4 | Company Presentation

HV Motors

Samicafilm ® tapes A complete range of mica tapes for all needs. 315.14

315.15-11

F2-90

F2-90+

315.23-11

Thickness

mm

0.09

0.09

0.09

0.09

0.09

Total weight

g/m2

131

135

124

126

126

Samica

g/m2

75

75

65

65

50

Polyester film g/m2

42

42

17

17

17

mm

0.03

0.03

0.0127

0.0127

0.0127

g/m2

-

-

32

32

32

mm

-

-

0.023

0.023

0.023

g/m2

14

18

10

12

27

No

Yes

No

Yes

2 X yes

Resin Adhesive

5 | Company Presentation

Samicafilm ® taped wires

HV Motors

Examples of insulation design with Samicafilm® wires: Wire

Bare copper

Enamel -led copper grade 2

Samicafilm®

Insulation design

Max. thickness increase due to insulation Unpressed

Pressed 0.30 mm

315.14 315.15-11

2 buttlapped layers

0.36 mm

F2-90 F2-90+

3 buttlapped layers

0.54 mm

F2-90 F2-90+

1 halflapped layer

0.50 mm

6 | Company Presentation

Rated voltage

13.8 kV

 0.43 mm 







0.43 mm 

VPI Insulating systems for HV motors

HV Motors

Von Roll offers three VPI insulating systems for high voltage motors: Epoxy anhyddride system

Catalyzed Epoxy

Polyesterimide system Samicabond®

Class

F

F

H

Mica Tape

Accel.

Non Accel.

Non Accelerated

In both cases Von Roll offers complete insulation systems with all needed materials:

All systems have been tested for compatibility as well thermal / mechanical / electrical ageing. All systems can be processed with state of the art machines.

7 | Company Presentation

7




Wires




Mica tapes




Auxiliary tapes




Resins




Conductive / Semi-conductive tapes




Composites

Worldwide use of VPI resins

HV Motors

Polyester

Epoxy Hybrid

Epoxy Anhydride

Catalyzed Epoxy

Polyesterimide

Silicone

F

F

F

F

H

220

Average

Average

Average/ High

Average/ High

High

Average/ High

RT

5-10°C

< RT

< RT

RT

RT

Cure cycle

Average/ Long

Average/ Long

Average

Average/ Long

Short

Long

Mechanical properties

Average

Average/ Good

Average/ Good

Average/ Good

Average/ Good

Poor

Flexibility

Average

Average/ Good

Average/ Good

Average/ Good

Average

Good

Electrical properties

Average

Good

Good

Average/ Good

Good

Good

Estimated sales volume worldwide (tons/year)

500

150

1000

150

150

100

Price (€/kg)

4-6

7-9

6-8

8-10

6-8

30-40

Thermal class Shelf life Storage temperature of resin

8 | Company Presentation

8

Approx. prices of VPI resins Price (€/kg)

HV Motors

100

50

Silicone

10

Epoxy

5

1 100

Polyesterimide

Polyester

120

140

160

180

200

Temperature index / class 9 | Company Presentation

220

240

260

VPI insulation systems for class F motors: Epoxy / anhydride resin Damisol ® 3407

HV Motors

3407 Liquid resin:

Viscosity at 23°C (mPas)

300-500

Special features of Damisol® 3407 are:

Viscosity at 50°C (mPas)

60-100


High tank stability at room temperature

Storage temp. Shelf life at 23°C

RT ≥ 1 year

Flash point

170°C

Gel time at 160°C

≥5h

Cure time at 170°C

8-10 h

Cured resin:

Thermal class

F

Application:

HV machines ≤ 30 kV




10 | Company Presentation


High flash point
Low viscosity
Fast curing with accelerated mica tapes
Excellent electrical properties
High mechanical strength

VPI insulation systems for class F motors: Mica tapes to be used with Damisol ® 3407

HV Motors

Samicapor® 366.55-10

Samicapor® P 315.33

Samicapor® 374.15

mm

0.15

0.13

0.18

Total weight

g/m2

200

214

241

Samica

g/m2

160

160

160

Glass fabric

g/m2

23

-

23

Resin content

g/m2

17

12

38

Polyester fleece

g/m2

-

-

20

Polyester film

g/m2 µm

-

42 30

-

480

480

400

Thickness

Accelerator

11 | Company Presentation

mg/m2

VPI insulation systems for class F motors: Catalyzed Epoxy resin Permafil ® 74050

HV Motors

74050 Liquid resin:

Viscosity at 23°C (mPas)

500

Storage temp.

RT

Shelf life at 23°C Flash point Gel time at 171°C

≥ 1 year 53°C ≥ 16 min

Cure time at 170°C

6h

Cured resin:

Thermal class

F

Application:

HV machines ≤ 30 kV




12 | Company Presentation

Special features of Permafil® 74050 are:
High tank stability at room temperature
Low VOC emissions
New technology
Very stable formulation
Excellent electrical properties
High mechanical strength

VPI insulation systems for class F motors: Mica tape to be used with Permafil ® 74050

HV Motors

Mica Mat® 2432XS

Mica Mat® 2404XS

Thickness

mm

0.16

0.16

Total weight

g/m2

211

232

Samica

g/m2

160

180

Glass fabric

g/m2

32

32

Resin content

g/m2

19

20

13 | Company Presentation

VPI insulation systems for class H motors

HV Motors

Von Roll’s class H Samicabond ® insulation system for motors is composed of:
Damisol® polyesterimide VPI resins
Samicapor ® mica tapes
CoronaShield® conductive and semiconductive materials
Range of auxiliary materials The main advantage of the resins are:
High tank stability at room temperature due to a peroxide-free accelerator
Not susceptible to moisture
Low viscosity
Fast curing with non-accelerated mica tapes
Excellent electrical properties

14 | Company Presentation

VPI insulation systems for class H motors: Resins for the Samicabond® system

Liquid resin:

HV Motors

Damisol® 3032

Damisol® 3340

Damisol® 3308

Damisol® 3309

Viscosity (mPas)

200/300

300/500

150

170

Diluent

Styrene

Vinyl Toluene

Styrene

Vinyl Toluene

RT

RT

RT

RT

6 months

6 months

18 months

12 months

Storage temp. Shelf life at storage temp. Flash point Gel time 120°C Cure time

> 32°C 1.5 - 2 min. 8h/140°C

> 32°C 2 - 4 min. 8h/150°C

> 32°C

> 32°C

2 - 3 min.

2 - 4 min.

8h/130°C

8h/150°C

Cured resin:

Thermal class

H

H

H

H

Application:

Dry type transformers













LV machines ≤ 1 kV







o

o

HV machines ≤ 6.6 kV













HV machines ≤ 15.75 kV

o

o







Traction motors













15 | Company Presentation

VPI insulation systems for class H motors: Non accelrated tapes

HV Motors

Samicapor®

Samicapor® P

366.58

366.58-18

366.58-20

366.53-01

374.04

315.45

323.12

mm

0.15

0.15

0.17

0.12

0.18

0.14

0.18

Total weight

g/m2

192

213

224

153

241

214

251

Samica

g/m2

160

180

180

120

160

160

160

Thickness

(Calcined mica paper)

Glass fabric

g/m2

23

23

32

23

23

-

-

Resin content

g/m2

9

10

12

10

38

12

20

Polyester fleece

g/m2

-

-

-

-

20

-

20

Polyester film

g/m2 µm

-

-

-

-

-

42 30

50 36

16 | Company Presentation

Resin-rich insulation systems for high voltage motors

17 | Company Presentation

HV Motors

Resin-rich insulation: Samicatherm ® Samicatherm®

Samicatherm® P

HV Motors

Mica Mat®

Filosam® L

Samicafle x®

366.28

366.32

315.20

77984

77956

326.57-50

366.18/19

mm

0.19

0.28

0.16

0.2

0.147

0.13

0.14/0.18

Total weight

g/m2

303

458

290

193

206

177

150/215

Samica

g/m2

120

240

150

153

109

75

75/120

calcined

uncalc.

calcined

calcined

calcined

calcined

calcined

Long.lglass strands

Long. glass strands

23 52/72 35/33

Thickness

Glass fabric

g/m2

32

32

-

31.2

Resin content

g/m2 %

113 43

148 35

70 28

50 33%

27%

50 28

Epoxy

Epoxy

Epoxy

Epoxy

Polyester

Epoxy

Silicone

-

-

32 23

9/9 6/6

35/17 50/13

-

F

H

Resin type Polyester film(s)

g/m2 µm

Polyester Mat

g/m2

Thermal class

18 | Company Presentation

27 F

F

F

F

Corona Protection

HV Motors

Laminated stator core

Slot exit

Copper conductors Main wall insulation

19 | Company Presentation

~

Voltage ≥ Partial Discharge Inception Voltage (PDIV)

Corona Protection

HV Motors

Laminated stator core

External corona protection

Slot exit

Copper conductors

~

Main wall insulation End corona protection

20 | Company Presentation

Conductive materials for external corona protection

HV Motors

Conductive tapes CoronaShield®

215.51

215.51-03

215.55

215.63

VPI* and resin-rich

VPI* and resin-rich

VPI and resinrich

Slot liner

mm

0.10

0.10

0.085

0.17

Total weight

g/m2

80

75

80

113

Polyester fleece

g/m2

60

60

60

70

Resin content

g/m2

20

15

20

43

≥ 10

≥ 10

≥8

≥5

200-400

400-1000

200-400

200-400

Thickness

Elongation Surface resistivity

21 | Company Presentation

% Ω cm/cm

Conductive tape based technology: CoronaShield® NB CoronaShield ® NB 2500 NB 70 VPI and resin-rich

Thickness

mm

0.070

HV Motors

Von Roll and DuPont have joined their R&D’s to create new materials for our industry. CoronaShield ® NB is an example of this development. Advantages are:
High resistivity
Better ageing compared to conventional tapes

Total weight

g/m2

54

Resin content

g/m2

-

Surface Resistivity at TEA 17 kV/175°C 8000

Shrinkage Surface resistivity

7000

N/cm % Ω cm/cm

≥35 0 1500 - 3000

R in Ohm cm/cm

Tensile strength

6000 5000 4000 3000 2000 1000 0 0

Thermal class

220

200

400

600 t in h

DuPont™ and NOMEX® are trademarks or registered trademarks of DuPont and its affiliates.

22 | Company Presentation

CoronaShield Conventional

c

800

1000

Materials for slot exit : Semi-conductive materials

HV Motors

Semiconductive tapes CoronaShield®

Voltaqe distribution along end windings:

217.21

217.22

217.31

B-stage tape

B-stage tape

Fully cured

mm

0.22

0.22

0.25

Total weight

g/m2

360

360

360

Polyester fleece

g/m2

70

70

70

Resin content

g/m2

290

290

290

Thickness

Shrinkage after 2h at 160°C Curing conditions

23 | Company Presentation

%

≥6

≥6

≤5

2 h / 165°C

2h/ 165°C

-

Without stress grading tape CoronaShield 217.01 / 217.21 CoronaShield 217.13 / 217.31 CoronaShield 217.02 / 217.22

Corona protection: Slot packing materials

HV Motors

Flexible or rigid conductive materials are used to provide a good fit of the coil in the slot.

Conductive Vetronite® 432.10/11 or Conductive ripple springs 92.200

24 | Company Presentation

Support materials

HV Motors

A number of support materials are used for the construction of high voltage motors:


Stack consolidation tapes and resins
Finishing tapes
Bracing cords
Stator and rotor slot wedges
Coating and finishing varnishes

25 | Company Presentation

Support materials: Stack consolidation

HV Motors


Thermopreg® 251.78 is an epoxy resin impregnated woven glass prepreg with a high resin content. It is used for the consolidation of the conductor stacks. The resin fills the interstices in the coil before curing.

Glasoflex
Polyester fleece tape 101.74-07 is applied for stack consolidation of conductors insulated with ® 261.10Samicafilm®. Consolidation is done without release 03

film and the fleece tape is not removed after the process. It helps to give a good bonding to the main insulation.

Thermopreg® 251.78 or Polyester fleece tape 101.74-07 (if conductors are insulated with Samicafilm) 26 | Company Presentation


Glasoflex ® 261.10-03 is an epoxy resin impregnated glass fleece used as vertical and horizontal separator.
Damival® 15182 is a two-component epoxy resin which can be used for stack consolidation.

Application of anti-corona products and endwinding tapes Epoflex® endwinding tape

HV Motors

Epoflex® is used as a protection tape for the endwindings.

Conductive There are three types of Epoflex® tape depending on the application. They consist of:
an epoxy resin impregnated polyester fleece,
polyester/glass fabric
poly-ester/glass fabric covered with a polyester film.

CoronaShield tape

Mica tape 27 | Company Presentation

The tapes shrink during curing ensuring the consolidation of the main wall, providing a smooth surface and helping to improve the contact between the layers of the anti-corona tape(s).

Epoflex® endwinding protection tapes

HV Motors

Epoflex® 215.01 For resin rich and soft cell

219.61-10 For resin rich

324.03 For VPI

mm

0.19

0.18

0.09

Total weight

g/m2

220

180

76

Polyester fleece

g/m2

40

-

-

Polyester / glass fabric

g/m2

-

61

25

Polyester film

g/m2

-

-

28

Resin content

g/m2

180

119

23

Elongation

%

≥ 10

≥ 20

≥ 20

Shrinkage at 2h / 70°C Shrinkage at 2h / 120‘°C

% %

-

≥1

≥1 ≥ 20

Thickness

28 | Company Presentation

Support materials: Slot wedges

HV Motors

Stator and rotor slot wedges are supplied in full size sheets or machined according to the customer‘s drawings. Materials used for high voltage motors are:
Delmat® 68.660 / epoxy)

(Glass mat


Delmat® 68.420 mat / epoxy)

(Glass


Vetronite® 64.120 (Glass fabric / epoxy)
Vetroferrite ® 432.20/21 (Magnetic slot wedges, glass fabric / ferrite / epoxy) 29 | Company Presentation

Support materials: Coating and finishing varnishes

HV Motors

Coating and finishing varnishes are used to protect coils, housings and laminations against dirt and moisture. They are air or oven drying. Varnishes mostly used are:
Coating varnish Damicoat® 2404 HFP for class F motors
Coating varnish Damicoat® 2407 for class H motors

30 | Company Presentation

Production equipment

HV Motors

Von Roll offers the complete range of production equipment for high voltage coil manufacturing:
Loop winding machines
Coil spreading machines
Taping machines
VPI plants
Drying ovens The flat coil technology provides another possibility for a significant cost reduction in high voltage coil manufacturing.

31 | Company Presentation

Flat Coil Production center

HV Motors

Loop Winder

Taping Machine Forming Machine

Wire Dispenser 32 | Company Presentation

Testing

HV Motors

Von Roll tests in its own laboratories all materials as well as complete insulation systems according to a variety of international standards such as the IEC, the UL® and specific customer standards. Our customers profit from our experience to modify, develop and improve their electrical insulation systems. Von Roll provides the following evaluation tests:
UL 1446/IEEE117 up to 1 kV
IEEE275/IEEE429 up to 6.9 kV
IEE1043 voltage endurance up to 50 kV
NEMA MG1 immersion test
IEC60034 testing
Electrical life graphs of systems
Mechanical life graphs (thermal index IEC 216) of systems
Multistress ageing
Failure analysis
Manufacturing parameters for resin rich and VPI technology

33 | Company Presentation

Von Roll: The Full Technology Provider

HV Motors

Von Roll is the unique partner for:
Insulation system components (flexible materials, conductors and composites)
Insulation systems
Manufacturing technology and equipments (M Tec)
Consulting & application engineering
Testing
Training

We Enable Energy

34 | Company Presentation