ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 

Report data
 

Report Customer point of contact

Date of report 29th April 2016 Company EGESUR S.A.
Prepared by Maitrayi Name
Mail Dm.leap.coe@in.abb.com Fax
Measured by ABB Peru E-mail
Measurement date
Machine name
Serial number 6410193
Tag ID GENERADOR N°1
Report No 416005

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
Overall summary and recommendations:

Summarized observations
 

 There is evidence of charge storage in winding closer to slot and slot end areas.
 There are no signs of cracks or localized damage in the insulation as is seen from the volume resistivity values obtained.
 There is no evidence of damage/erosion to the corona protection shield used in the slot section.
 There is no evidence of damage/erosion to the stress grading system at the slot ends.
 There is evidence of presence of mobile ions in the insulation as a result of de-polymerization of resin.
 The partial discharge patterns provided indicate dominant de-lamination discharging.
 The extent of discharging air spaces, measured by the discharging void volume content, is higher than (>0.5) what is
normally observed in epoxy-mica insulation systems.
 On the basis of the operating data and the measurements performed on the machine and based on the life time expectancy
analysis and the condition of the machine insulation, the machine has been in operation for a period of around 19.34% of
the expected lifetime of the stator winding.
 The expected life of the stator winding insulation is estimated to be an additional 223700 equivalent hours with the
existing operating conditions. The above life expectancy analysis is done with a confidence level of 80%.

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
Recommendations

The machine has consumed approximately 19 % of its designed life. Considering the present machine condition and its past
maintenance history it is recommended plan a level 3 intervention for the machine within a period not exceeding 6 months. Such
maintenance requires opening of end-covers.

The following maybe done in the intervention:

Inspection of the slot and slot-end areas:

 The slot end areas should be inspected for any evidence of PD at slot exits. The un-wedged portions of the slot areas and slot
end areas should be inspected for any signs of damage of the corona protection shield using a boroscope
 It is suggested that the inspection be aided with a corona detection probe for localization of significantly contributing discharge
sites
 Once the sites of pd activity are located, an evaluation should be performed to determine the possibility of measures that could
help reduce the growth of related damage.

Inspection of the end-winding areas:

 The areas around ties/lashing supports of the stator end-windings should be inspected for partial discharge damage and for
developing looseness of the supporting ties.
 End-winding portions of the stator should be examined for localized areas of discoloration

Once the sites of pd activity are located, an evaluation should be performed to determine the possibility of measures that could help
reduce the growth of related damage.

The measures may include but not be limited to:

- The use of conductive varnishes/paints to reduce localized pd activity

Other Inspections:

In addition to providing a maintenance opportunity for the recommended maintenance actions, the inspection helps cover the
portions of the winding that cannot be evaluated in a LEAP Standard inspection e.g. end-winding support system, specific localized
damage areas, etc.
However, considering that no outage maintenance has been performed, the other machine components (bearings, rotor windings,
etc), also need to be inspected. It is suggested that the inspection and maintenance be performed during the recommended outage.

Further assessment:
It is advised to perform a LEAP Standard inspection in a time period not exceeding 24,000 equivalent operating hours.

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
Table of contents
Report data ....................................................................................................................................................................................... 1
Overall summary and recommendations: .......................................................................................................................................... 2 
Machine Details ................................................................................................................................................................................. 5 
Other Information .............................................................................................................................................................................. 5 
Life expectancy analysis program ..................................................................................................................................................... 6 
Life model: ......................................................................................................................................................................................... 6 
Comments ......................................................................................................................................................................................... 8 
Measurements & analysis ............................................................................................................................................................... 10 
Polarization-Depolarization current analysis (PDCA) ...................................................................................................................... 10 
TAN-DELTA & Capacitance Analysis (TDCA) ................................................................................................................................. 13 
Non-linear insulation behavior analysis (NLIBA) ............................................................................................................................. 15 
Partial discharge analysis (PDA) ..................................................................................................................................................... 17 
LEAP - Additional Information: ........................................................................................................................................................ 18 
Glossary .......................................................................................................................................................................................... 19 

   

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
Machine Details
 

Machine name:
Customer EGESUR S.A.
Machine Identification/Tag ID GENERADOR N°1
Serial No 6410193
Make/Manufacturer TOSHIBA
Model/Type TAK S.RC
Power Rating (kW) 14000 KVA
Voltage (kV) 11
Current (A) 735
Frequency (Hz) 60
Speed (rpm) 720
No. of Poles 10
Power Factor 0.85
Insulation Class F
Manufacturing Year 4/1/1965 12:00:00 AM
Commissioning Year 2/1/2007 12:00:00 AM
Maintenance History Overhauled 8 years back
 

Other Information
 

Machine details
Stator Insulation Type Epoxy-Resin (Resin Rich)
Corona Paint on coil surface Present
Stress Grade System at Slot exits Employed
Machine Tested Immediately after Overhaul/Repair No
Machine in assembled condition (during testing) Yes
Winding Temperature (during testing) 35°C
Ambient Temperature (during testing) 17°C

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
Life expectancy analysis program
 

Operational hours(As per given data) 28333 

Starts/Stops 2529 
Equivalent hours 53623 
Maximum winding temperature(°C) 70
Life used (%) 19.34%

Life model:
 

LIFE EXPECTANCY ANALYSIS @ 70 deg C

(With 80 % Confidence Level)
100

90 Maximum potential
life estimate
80

70 Present Life
Estimate
LIfe Index

60

50

40

30

20

10

0
0 50 100 150 200 250 300 350 400

Equivalent Hours ( x 1000)

Insulation degradation curve (designed) Remaining Life (present) Present Life

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
On the basis of the operating data and the measurements performed on the stator, the expected life of the stator winding insulation,
with the existing operating conditions, is estimated to be an additional

Remaining life: 223700 Equivalent operating hours

The above life expectancy analysis is done with a confidence level of 80% and considers some points as under:
a) The above estimation is based on the measurements performed by ABB and historical and operating data of the machine,
made available to ABB, considering steady state conditions only.
b) The life estimation is based on the assessment of the stator ground-wall insulation only. Models are used that describe
known wearing out and ageing processes of the ground-wall insulation of the stator windings.
c) It is assumed in the analysis, that future operating conditions of the machine will be similar to the historical operating data
made available to ABB.
d) Any transient stresses that may be manifested on the windings, such as switching and/ external line transients, etc., could
result in insulation failure prior to estimated life (pre-mature failure).
e) The aim of life estimation study is aimed at developing a maintenance plan for the stator winding. ABB disclaims warranty
of merchantability or fitness for intended purpose.
f) LEAP is a process and not a one time event. Periodic measurements and analysis over time will help reduce the effect of
the assumptions made and could increase the confidence level of the analysis.

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
Comments
 

Contamination
There is evidence of charge storage in winding closer to slot and slot end areas as can be seen from the following:

 The charge storage in the slot regions as determined from the PDCA, is found to be higher than what is normally observed,
and could be attributed to charge storage in slot region that could have resulted from contamination in the slot/slot end
regions or could also be due to charge storage in the air spaces between coil and slot.
 The dispersion ratio is greater than what is normally observed in epoxy mica insulation system. On closer examination,
this is largely due to high charge storage in the slot region.
 The Ic/Ir value obtained when all three phases are simultaneously tested is indicative of the nature of the dominant current
that flows on the surface of the end windings at the slot ends. This current is seen to be predominantly capacitive in
nature,indicating that the contaminant at the slot ends,could precipitate charge storage effects and could essentially be in
the form of oil grease or other non conductive contaminants.
 The volume resistivity values are within what is normally observed for the class of insulation used and possibility of cracks
or localized defects in insulation is remote.

Condition of corona protection shield

There is no evidence of any damage to the corona protection shield used in the slot section as can be seen from the
following:

 The partial discharge activity, as recognized from the partial discharge patterns recorded and the magnitudes of the
discharge activity, is not that of slot discharge activity.
 There is some evidence of lack of electrical contact of the outer layer of the windings (corona protection shield) in the slot
area with the slot from the Q1/Q2 ratios. This is attributed to presence of impregnating resin in localized areas between
the corona protection shield and the slot or could also be due to accumulation of charges near the electrodes i.e. in the air
spaces between coil and slot, and not due to damage of the corona protection shield.

Condition of stress grade system

There is no evidence of any damage to the stress grading system used at the slot exits as can be seen from the following:

 The partial discharge patterns obtained do not indicate any slot end or surface discharge activity.
 The variation of tan delta and capacitance with voltage below discharge inception, is seen to be linear in nature. This
behaviour is essentially governed by the surface properties of the windings at the slot ends.

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 

Ageing of resin
There is evidence of the presence of mobile ions in the insulation as can be seen from following:

 The harmonic patterns obtained on analyzing the instantaneous admittance of the insulation is representative of the
predominance of non-linear effects due to abnormal accumulation of mobile ions within the insulation system.
 The changes observed in the harmonic patterns of the instantaneous admittance with increase in the test voltage are
indicative of improved contact of the slot corona protection shield with the stator core at higher test voltages.
 The ageing factor calculated is in the normal range and does not reflect any significant accumulation of mobile ions near
the electrodes.
 From the extent of de-polymerization of the resin, the state of ageing of the resin can be described as "new to mid-life”.

Delamination
There is evidence of presence of de-laminations in insulation which are seen to be discharging as can be seen from the
following:

 There is evidence of discharging of voids/delaminations within the insulation from the partial discharge patterns recorded,
and internal discharging is seen to be the most dominant discharge pattern. From the patterns recorded when all three
phases are simultaneously tested, the voids or delaminations are seen to be distributed through the volume of the insulation
 The discharging void volume content calculated from tan delta and capacitance variations with voltage when all three
phases are simultaneously tested, and estimated at the line to ground test voltage, is on the higher side (> 0.5%) when
compared with similar epoxy mica based insulation systems.

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
Measurements & analysis
 

Polarization-Depolarization current analysis (PDCA)

 

Test voltage: 5000 volts U V W UVW Normal range

IR (Insulation Resistance) [MΩ] 5180 5140 5310 1780 ---------
PI (Polarization Index) 7.92 7.73 8.32 10.34 >2
T1 (Ion Migration Time Constant) [secs] 20.63 21.18 21.56 22.74 10-30 Sec
T2 (Slow Relaxation Time Constant) [secs] 108.56 105.32 104.75 114.15 65-150 Sec
T3 (Interfacial Polarization Time Constant) [secs] 649.58 652.40 650.23 748.27 300-1000 Sec
Q1 (Charge - Ion Migration) [%] 12.58 12.73 11.44 8.70 <7%
Q2 (Charge - Slow Relaxation) [%] 16.57 11.68 11.43 12.27 < 10 %
Q3 (Charge - Interfacial Polarization) [%] 24.89 13.67 13.04 13.30 < 20 %
Q1/Q2 75.90 >100 >100 70.87 55-65 %
Q2/Q3 66.56 85.45 87.61 92.27 55-65 %
AgF (Ageing Factor) 58.17 59.38 63.75 77.09 35-100
Ic/Ir -2.26 1.95 -4.04 7.45 ----------
Co/C (Dispersion Ratio) 1.54 1.38 1.36 1.34 < 1.25
I (Charging Current At Long Times) [μA] 0.05 0.06 0.05 0.15 ----------
ρv (Volume Resistivity) [Log Scale] 14.63 14.57 14.64 14.61 > 14

   

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
 

Polarization-Depolarization Currents U Phase

Polarization-Depolarization Currents
U PHASE

100
Pol-Depol Currents (microAmp)

10

0.1

0.01
1 10 100 1000

Time (sec)

Charging Discharging

Polarization-Depolarization Currents V Phase

Polarization-Depolarization Currents
V PHASE

100
Pol-Depol Currents (microAmp)

10

0.1

0.01
1 10 100 1000

Time (sec)

Charging Discharging

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 

Polarization-Depolarization Currents W Phase

Polarization-Depolarization Currents
W PHASE

100
Pol-Depol Currents (microAmp)

10

0.1

0.01
1 10 100 1000

Time (sec)

Charging Discharging

Polarization-Depolarization Currents UVW Phase

Polarization-Depolarization Currents
UVW PHASE

100
Pol-Depol Currents (microAmp)

10

0.1

0.01
1 10 100 1000

Time (sec)

Charging Discharging

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 

TAN-DELTA & Capacitance Analysis (TDCA)

 

Voltage U Phase Voltage V Phase

(kV) TD (%) CAP (pF) (kV) TD (%) CAP (pF)
0.50 1.41 111000 0.50 1.37 111800
1.04 1.36 111300 1.01 1.31 112100
1.51 1.39 111400 1.5 1.34 112100
2.04 1.47 111500 2.04 1.42 112200
2.54 1.54 111600 2.51 1.46 112400
3 1.59 111700 3 1.52 112500
3.53 1.69 111800 3.47 1.6 112500
3.97 1.77 111900 4.07 1.70 112700
5.06 1.99 112200 5.08 1.89 112900
6.37 2.33 112600 6.36 2.22 113300

Voltage W Phase Voltage UVW Phase

(kV) TD (%) CAP (pF) (kV) TD (%) CAP (pF)
0.50 1.31 111700 0.51 1.17 328800
1.04 1.30 112000 1.02 1.23 329100
1.5 1.31 112000 1.52 1.30 329600
1.99 1.37 112100 2.04 1.40 329900
2.53 1.42 112200 2.51 1.46 330200
3.01 1.51 112300 3.01 1.54 330500
3.51 1.56 112400 3.52 1.64 330800
4.04 1.67 112500 4.02 1.72 331000
5.03 1.85 112700 4.97 1.92 331800
6.34 2.20 113200 6.36 2.31 333300

Calculated parameters

U V W UVW
Effective Phase Shift (deg) 21.43 18.13 23.68 36.41
Base Tan Delta TDo (%) 1.31 1.27 1.23 1.08
Base Capacitance Co (pF) 110960 111727 111674 328458
Discharge Inception Voltage (kV) 3 3 3 3.01
Discharging Void Volume Content (%) 0.84 0.80 0.78 0.84
Effective Phase of Discharge (deg) -89.84 -83.03 71.58 64.30

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
 

TAN-DELTA & Capacitance measurements

2.5

2
TAN DELTA (%)

1.5

0.5

0
0 1 2 3 4 5 6 7
Voltage (kV)

U V W UVW

113500 334000

Capacitance ‐ UVW Ph. (pF)
Capacitance ‐ Ind Ph. (pF)

113000 333000

112500 332000

112000 331000

111500 330000

111000 329000

110500 328000
0 1 2 3 4 5 6 7
Voltage (kV)

U V W UVW

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
Non-linear insulation behavior analysis (NLIBA)
 

Odd Harmonics –Low Voltage

10
9
ODD HARMONIC MAGNITUDE 

8
7
(arbitrary units)

6 U

5 V
4 W
3 UVW
2
1
0
1 3 5 7 9 11 13 15

Odd Harmonics – High Voltage

10
9
ODD HARMONIC MAGNITUDE 

8
7
(arbitrary units)

6 U

5 V
4 W
3 UVW
2
1
0
1 3 5 7 9 11 13 15

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
Even Harmonics- Low Voltage

10
9
EVEN HARMONIC MAGNITUDE 

8
7
(arbitrary units)

6 U

5 V
4 W
3 UVW
2
1
0
2 4 6 8 10 12 14 16

Even Harmonics – High Voltage

12
EVEN HARMONIC MAGNITUDE 

10
(arbitrary units)

8
U

6 V
W
4
UVW

0
2 4 6 8 10 12 14 16

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
 
Partial discharge analysis (PDA)
 

Phase U @ 6.37 kV Phase V @ 6.37 kV

Phase W @ 6.34 kV Phase UVW @ 6.38 kV

 

   

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 ABB Motors and Generators

Life expectancy analysis report - Stator winding insulation

 
LEAP - Additional Information:
Polarization & de-polarization current analysis (PDCA)
References:
̵ IEEE 43: 2000
̵ “Diagnosis of insulation health of rotating machines” by Cajetan Pinto, Maciej Wnek, CWIEME Proceedings, 2000.
̵ "An Improved Method of detecting contamination of HV stator windings in the field" by Pinto C 18th E/EIC conference
proceedings - Chicago 1989

Measurement of capacitance and tan delta

References:
̵ IEC 60894/ IEEE 432: Guide for a test procedure for measurement of loss tangent of coils and bars for machine windings.
̵ “Estimation of void content in stator coils of high voltage rotating machines”., C. Pinto, Dr. A. D. Mokashi, 19TH EEIC/ ICWA
CHICAGO, 1989

Partial discharges analysis

References:
̵ IEC 60034-27:2006
̵ IEEE Std 1434-2000 - Trial Use Guide to the Measurement of Partial Discharges in Rotating Machinery
̵ F.H. Kreuger, E.Gulski and A.Krivda, “Classification Of Partial Discharges”, IEEE Trans. On Electrical Ins., Vol. 28 No. 6, Dec
93
̵ B. Fruth, D. Gross, "Partial Discharge Signal Generation, Transmission and Acquisition", IEE Proc.-Sci. Meas. Technol., Vol.
142, No.1, January 1995, Invited Paper following the Int. Conf. on Partial Discharge, University in Canterbury
̵ B.Fruth, L. Niemeyer, "The Importance of Statistical Characteristics of Partial
Discharge Data", IEEE Trans. on Electrical Insulation, Vol.27, No.1, February 1992
̵ B. Fruth, J. Fuhr, "Partial Discharge Pattern Recognition - A Tool for Diagnosis and Monitoring of Ageing", CIGRE, paper 15/33-
12, 1990

Non-linear insulation behavior analysis

References:
̵ C. Pinto, “A Generalized Approach For Study Of Non-Linear Behavior Of Stator Winding Insulation”. ICSD '98 - 6th International
Conference On Conduction and Breakdown in Solid Dielectrics by IEEE.
̵ C. Pinto, “A generalized approach to study non-linear insulation behavior of stator windings using ac measurements: - ELROMA
2008. 2nd prize winning paper.
 

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 ABB Motors and Generators
Life expectancy analysis report - Stator winding insulation
Glossary
Charge storage: The
charge storage takes place
due to various mechanisms
such as,
Interfacial polarization (Q3)
in endwinding region
Space charge polarization
(Q1) and Interfacial
polarization (Q2) in slot
region
Space charge polarization: The alignment of electric dipoles
within the insulation on application of electric field results in
accumulation of charges in a region such as near the electrodes
(copper and iron) in the slots and in the end winding sections, due
to the inefficient exchange of charges in these areas. This is
called space charge polarization.
Interfacial polarization: The migration and accumulation of
charge between two different dielectrics that have different
dielectric constants (such as that between layers of mica-epoxy,
between machine insulation and contaminant, between machine
insulation and airspace, etc) gives rise to interfacial polarization.
The Q2 charges usually reflect charge accumulation at interfaces
within slot section, while Q3 charges usually reflect charge
accumulation on the end-winding, on the basis of a distributed
capacitor-resistor model that is used to describe surface
conditions on the end-winding
The proportional distribution of these charges (as seen from
values of Q1/Q2 and Q2/Q3) gives an indication of the charge
storage process that may be dominant. A greater proportion of
charge stored near the electrodes could possibly indicate (high
Q1/Q2, for thermosetting systems), a loss of electrical contact of
the outer surface of the coil with the core. This may be due to high
coil side clearances/ wedge looseness or damage/ degradation/
modification of the properties/erosion of the slot discharge
prevention shield or even an insulating layer between the corona
protection and the slot. It could also indicate possible overheating
of the coil surface in contact with the core, or aging/overheating
of the insulation in close proximity of the conductor stack, large
gaps between the ground-wall insulation and the conductor stack.
Ic/Ir Ratio: Ic/Ir ratios are calculated by considering the
current in the range of 1000 sec expressed as a power law
curve, and essentially is representative of the flow of
capacitive and resistive currents on the end-winding surface.
The model used, most closely represents the situation when
all three phases are simultaneously tested. The analysis is
meaningful only when the presence of contaminants is
indicated from other analysis such as charge storage. The
ratio is meant to be indicative of the nature of the contaminant
at the slot ends. Values near 1 and less than 1 have been
observed in windings contaminated by carbon
particles/carbonized oil (conductive contaminants) or other
conductive dust deposition at the slot ends. In case of
oil/grease type contaminants, discontinuity in the stress
grading system at the slot ends, the values are greater than
1. Negative values are at times observed due to the creation
of homopolar charges at the slot end regions, due to the
present of moisture in the contaminant or on the surface of
the windings or even when there is iron oxide in the
contaminant.
Aging Factor (AF): This factor gives an indication of the state
of resin in close vicinity of the electrodes, in terms of the
concentration and mobility of its mobile ions. The values are
around 100 for new machines. However, when reduced
values are obtained it indicates de-polymerization of resin and
aging of insulation near the electrodes. Extremely low values
of AF (<35) could also be obtained if the windings are
contaminated with dirt and the contaminant penetrates into
the insulation, in and around electrode regions.
Ion Concentration index (CI): There are always mobile ions
found within the insulation, but these are generally dispersed
within the insulation. During a polarization process these
charges get trapped in certain regions of the winding
insulation. The number of mobile ions per unit volume is
represented by the Ion Concentration Index. The greater the
ion concentration, the higher is the possibility of charge
injection within the insulation. The ion concentration index is
generally reflective of the charge concentrations near the
electrodes, or at interfaces. The permissible values lie
between 0.015 to 0.025.
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 ABB Motors and Generators
Life expectancy analysis report - Stator winding insulation
Dispersion ratio: The
ratio of the capacitance
required to store the
charge obtained from
the winding during the
discharging process, to
the geometrical
capacitance of the
windings, is referred to
as the Dispersion ratio.
Check for contamination on the Values computed for
endwinding at ties/evolutes.
clean and dry insulation normally do not exceed 1.2. Dispersion
ratio values have been seen to exceed 1.2
a) if there is a dispersive contaminant present in or on the
windings, e.g. carbon, particularly when mixed with oil, or
moisture present in the contaminant or in the windings
b) if there is a loss of contact of the outer surface of the coil with
the core, and the presence of an insulation between the anti
corona shield and core (as is sometimes seen in VPI
windings)
c) in cases of advanced aging of the insulation.
Tan delta: Tan  is a measure of the energy spent in the
dielectric medium as a result of dipolar polarization, interfacial
polarization, space charge polarization and partial discharge
effects. Tan delta variations with voltage occur as a result of
contamination, ageing, lack of resin cure, delaminated insulation,
stress grading systems, and partial discharges, and hence is
useful indicator of the insulation health.
Discharge inception voltage: It is the voltage at which partial
discharge activity is initiated. The point generally coincides with
the point, which the tan d curve with voltage suddenly rises
sharply.
Void volume content: Discharges in the insulation could occur
in voids or air spaces that may be present in the insulation system
if the electric field and air gap size (based on Paschen’s Law)
would permit. The volume of discharging voids in the insulation
reflects the integrity of the insulation, and is a good indicator of
the insulation health. The discharging void volume content can
be evaluated from the variation of the capacitance and tan 
above discharge inception.
 Effective phase of discharging: The effective phase of
discharging is estimated from the variation of tan delta and
capacitance with voltage above discharge inception. The
effective phase is calculated on the basis that all losses and
capacitance changes due to partial discharge effects (from
internal slot or surface discharging) could effectively occur at an
effective phase angle, which is calculated.
Effective phase shift: The effective phase shift is
computed from the variation of C-Tan measurements
with voltage. In the case of machines employing stress
grading systems at the slot ends, the variation of
capacitance and tan delta with voltage below discharge
inception is seen to be linear. The effective phase shift
characterizes the stress grading system, and therefore
indicates whether properties of stress grading system
are modified / deteriorated. Note that when values are
greater than 35 deg, the variations are influenced by the
conductive properties of the stress grading system or the
agent of modification, at the slot exits. Similarly values
lower than 20 deg is indicative of capacitive influences.
Harmonic content: The instantaneous variation of the
insulation capacitance with time is plotted from the time
waveforms of the voltage and the current data obtained.
A harmonic analysis is performed on the instantaneous
capacitance-time variation waveform. Harmonic plots
are generally seen to be with even harmonic
predominance and with reducing magnitudes as the
harmonic number increases.
Even to Odd Ratio: This ratio helps us to identify which
harmonics (even or odd), are most dominant. Reasons
for non-linear behavior of the insulation could either be
conductive or charge storage based. Odd harmonic
predominance is seen when there are conductive
reasons for non-linear behavior, while even harmonic
predominance is indicated when the behavior is
controlled by charge storage effects.
Life expectancy analysis: A combined stress
phenomenological model, that is based on one proposed
originally by Simoni, Srinivas, et al, is used to assess the
extent of degradation of the insulation and perform a
lifetime expectancy analysis. The model accounts for
thermal, electrical and mechanical stresses, whose
relative effects on the life of the insulation are estimated
on the basis of the analysis from the measurements
performed, and from the operating and historical details
made available.
The theory stems from the fact that when stresses act
on the insulation of the stator windings, there is a
progressive deterioration of the strength of the
insulation. In other words, ageing is exhibited by a
progressive deterioration of the physical properties of
the insulation. Not all physical properties can give an
indication of the progression of ageing, except perhaps
those directly related to failure, e.g. electrical
breakdown strength and mechanical strength. If
stresses unable to produce a failure are considered
such as temperature or chemical exposure, other
failure
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 ABB Motors and Generators
Life expectancy analysis report - Stator winding insulation
criteria are selected that are related to electrical or mechanical
breakdown strengths. In any case, failure essentially occurs
when the selected property drops down to a limiting value, so
that a unique definition can be adopted for remaining life – the
time for the selected property to reach that point. This point is
generally related to the stresses that are developed in the stator
insulation during machine operation. In other words, when the
strength of the insulation deteriorates to a point where it equals
the developed stresses in the insulation, the insulation will fail.
The measurements performed during an inspection are
converted into parameters that can be related to the stresses that
are developed in the insulation, for example the extent to air
space within insulation would affect thermal, mechanical and
electrical properties of the insulation and thereby affect the
thermal electrical and mechanical stresses that are developed in
the insulation. This affects the rate of deterioration of the
insulation. To give another example, when the temperature of the
insulation increases, the rate of deterioration of the mechanical
strength of the insulation also increases. Therefore, based on the
knowledge of how parameters derived from measurements can
affect stresses, it is possible to estimate the rate of deterioration
of the strength of the insulation.
In the case of LEAP Standard measurements
performed, the parameters that have been used as
inputs from the analysis include the charge distribution
parameters, the volume resistivity, the discharging void
content parameters, partial discharge parameters and
data from the non-linear analysis. These parameters
are used together with operating data such as winding
temperature and the number of starts, to draw the line
describing the deterioration in insulation strength, as
indicated by the dashed red line.
It is generally assumed that at the time of commissioning
of the machine, there is no deterioration of the relevant
properties of the insulation. An initial life estimate,
indicated by the solid red line up to the time of inspection
and projected by the dashed green line, is made on the
basis of “normal” expected parameters (as derived from
operating data and the normal range values of
measurements such as those specified for LEAP
Standard inspections) at an early part of the machine
life.
21 
 ABB Motors and Generators
Life expectancy analysis report - Stator winding insulation
www.abb.com/motors&generators
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