MICADUR -COMPACT INDUSTRY

Insulation System for Rotating Electrical Machines

AC Machines
Voltages up to 15 kV
Temperature class F (155C)

The MICADUR -COMPACT INDUSTRY Insulation system

The MICADUR-COMPACT INDUSTRY

(MCI) insulation system is based on
the global Vacuum Pressure Impregnation (VPI) insulation method. The VPI
method itself has successfully demonstrated its reliability for many years
with machines used in all types of
applications and has achieved worldwide recognition for excellence.
The MCI insulation system is applied
to the entire range of form wound low
and high-voltage AC machines produced in ABB machine factories.
This includes:
Motors with outputs between 0.1 and
50 MW
Generators with outputs between 0.5
and 70 MVA
Condensers with outputs between 2
and 50 MVAr
Voltages up to 15 kV

The MICADUR-COMPACT INDUSTRY

Insulation system
has successfully
demonstrated its
industrial endurance
for many years,
achieving worldwide
recognition for
excellence.

MCIKey Features

Excellent Reliability: Years of dependable operational experience in a wide

variety of applications has proven the
excellent reliability of the system.
Proven System: Tens of thousands
of machines with the MCI-system have
been successfully in use by customers all over the world throughout the
years.
Outstanding Performance: The
dedicated mica insulation combined
with the global VPI process applying
special epoxy resin ensure a long-life
performance.

MCIProperties

Careful design and controlled manufacturing processes ensure that every

stator winding with the MCI technique
meets all relevant international standards. Inspections and tests are conducted during the coil manufacturing
and winding assembly to ensure a high
quality for the final product.

MCI meets all

international
standards
for industrial
machines

Thermal stress

The thermal endurance capability of

the MCI system has been proven by
more than 30 years of operation under
extreme conditions even with machines
fully utilizing thermal class F temperature rise. The thermal performance has
been determined per IEEE Std. 434 and
IEC 216-1 to 4 [1] by evaluating insulation properties over extended periods
at temperatures ranging from 160C to
200C. Based on these criteria, the MCI
system fully meets the requirements
of Thermal Class F expressed in IEC
85 [2]. MCI insulated stators have also
outstanding thermomechanical performance which has been confirmed in
severe cycling tests and in various applications even in arctic conditions.
Electrical stress

Each machine with MCI insulation

system is tested in various production
steps in order to ensure high reliability:
Dimensional checks on insulated
coils to assure proper fit in the slots.
Turn-to-turn insulation tests on each
individual coil prior to the VPI process.
High potential tests of windings prior
to VPI.
Final high potential test of windings
after VPI at voltages according to international standards.
Dissipation factor test according to
CENELEC for periodical check of VPI
and curing process parameters.
4

The MCI system has been extensively type tested in accordance with
IEEE Std 434 [3] and IEC publ. 727-1
[4]. The results indicate a significant
dielectric margin of safety according
to IEEE Std. 1043 [5].
Standard designs utilizing MCI well
exceed the international requirements of impulse voltage capability
as expressed in IEC 34-15 [6].

Ambient stress

Moisture: The penetration of epoxy

resin in the coils, overhang supports
and connections during the vacuum
pressure impregnation process produces a winding which is resistant
to very severe ambient conditions.
Further, as a standard option MCI
windings can be provided sealed
according to NEMA Std. 4, part 20.
Chemical Resistance: The materials used in the MCI insulation are resistant to acids and alkalines found
in many industrial applications.
Flammability: The MCI system has
proven to be virtually non-flammable according to relevant IEC and
ISO standards.
Radiation Resistance: All components of the MCI system exhibit a
high resistance to radiation (at least
107 Gy) making machines with MCI
insulation also suitable to nuclear applications according to IEC 544 [7].

The high quality

of the MICADUR

Mechanical stress

-COMPACT
INDUSTRY system

The

is assured by VPI

excellent mechanical strength

of the MCI coil overhang bracing
enables the system to withstand repetitive dynamic stresses of fast bus
transfer (e.g. rapid auto reclosure)
where coils may in the worst case
be subjected to extremely high outof-phase currents without damaging
effects.
5

MCIStructure and Manufacturing prior VPI

Tight compact construction

The coils are made from insulated

conductor wires. Corona resistant
polymer/mica combinations are
used to ensure excellent turn to turn
insulation.
The form wound coils are
wrapped with porous mica tape to
a thickness determined by the rated
voltage to provide a durable ground
wall insulation of high dielectric
strength.
Conductive corona protection
tape is applied on the stator slot
portion of the coils to avoid corona
discharges in the stator slot.
At higher rated voltages a semiconductive layer is applied to the
coil overhang beginning at the slot
exit in order to achieve uniform
stress grading of the voltage to
ground.
The unimpregnated soft coils are
inserted in the stator slots.
Highly resin absorbent fiberglass
cords are used for the coil overhang
support. After vacuum-pressure
impregnation (VPI) with epoxy
resin, the support system forms an
extremely rigid winding overhang
structure being able to withstand the
most severe service conditions.
Slot wedges retain the coils firmly
in the stator slots. For asynchronous
machines magnetic slot wedges enhance the power factor and operating efficiency of the machine.

MCIImpregnation Process
The vacuum pressure impregnation
and curing of the completely wound
and connected stator winding with the
specially formulated epoxy resin ensures a sealed and homogeneous insulation system, resulting in low dielectric
losses, high dielectric strength, excellent heat transfer and the elimination of
hazardous internal partial discharges.

Extensive research

Continuous Research and Development

& development is
the basis for ABBs
leadership in insu-

ABB

has traditionally maintained a

leading position in developing insulation systems for rotating machines. The
insulation R&D work is carried out in
our well-equipped insulation laboratories, which in addition to actual insulation development are active in international cooperation and standardization.

lation technology

Service and Maintenance of Windings

In general, MCI-windings require very
little maintenance. Usually it is most
important to prevent excess moisture
and dirt from entering the machine.
If the winding, however, has been
damaged then several choices exist to
put the machine back in operation:
1. In the case of minor damage, a
partial repair using spare coils may be
done. The spare coils are fabricated as
individual coils and they are available
on short notice.
2. In the case of widespread damage a
complete rewinding is recommended,
using the original MCI processing or a
full set of replacement coils.

References
[1] IEC 216-1 to 4: Guide for the Determination of Thermal Endurance Properties
of Electrical Insulating Materials
[2] IEC 85: Thermal Evaluation and Classification of Electrical Insulation
[3] IEEE Std 434: Guide for Functional Evaluation of Insulation Systems for Large
High Voltage Machines
[4] IEC publ. 727-1: Evaluation of Electrical Endurance of Electrical Insulation
Systems
[5] IEEE Std. 1043: Voltage Endurance Testing of Form wound Bars and Coils
[6] IEC 34-15: Impulse Voltage Withstand Levels of Rotating A. C. Machines
[7] IEC 544: Guide for Determining the Effects of Ionizing Radiation on Insulating
Materials

Power is guaranteed even in most

3BFP 001 980 R0101 REV B 06/2003

extreme conditions all over the

world by MICADUR-COMPACT
INDUSTRY insulation system.

The information and specifications contained in this brochure are subject to change without notice.