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Insulation System and Thermal Design of a Hermetically Sealed Turbo-

Generator Operating in a Small-Power CHP Plant

Conference Paper · June 2007

DOI: 10.1109/ICCEP.2007.384184 · Source: IEEE Xplore

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 Insulation System and Thermal Design of a
Hermetically Sealed Turbo-Generator Operating
in a Small-Power CHP Plant
V. Sihvo, J. Nerg and J. Pyrhönen
Department of Electrical Engineering, Lappeenranta University of Technology, P.O. Box 20 53851 Lappeenranta, Finland.

Abstract— Small CHP plants within the range of one
megawatt electric power and a few megawatts thermal
power might be well suited in supplying heat and electricity
for small communities. Hermetically sealed turbo-generator
improves the cost-effectiveness of such small-power CHP
plants. In such a structure, the low pressure, low
temperature steam from the turbine flows through the air-
gap of the generator. On the other hand, a hermetically
sealed turbo-generator sets very high demands for the
generator design. Steam in the air-gap is a substance, which
traditional insulating materials cannot tolerate. Also, the
thermal design of the machine requires special attention.
This paper introduces a turbo-generator design with steam-
resistant insulation system and proper thermal design to
operate in a hermetic small-power CHP plant.
Index Terms— AC generators, Insulation
I. INTRODUCTION
Turbo-generators play an important role in energy
conversion. They are used in almost every power plant
throughout the world to convert heat energy, created by
burning process or nuclear reaction, to electricity. In few-
megawatt power plants, the turbo-generator easily gets
relatively expensive. This is basically because the turbine
and the generator must have different environments: there
must be steam inside the turbine in order to rotate it and
there must be air or some other cooling medium inside
the generator, since it cannot withstand steam. At the
same time, these two are mounted on the same rotating
shaft with possibly a transmission between them. This
paper introduces a generator, which can tolerate steam.
When steam can flow also thorough the generator, the
structure is simpler and less expensive than the
conventional solution.
The political leaders of the world have recently been
encouraging to increase the use of renewable energy
sources, instead of fossil fuels. Also, the emissions
trading scheme set by the Europe Union favours
decentralized power production. Meanwhile, poor power
quality in public supply networks has caused problems to
high-tech industry [1]. In many countries, the electricity
supply industry has been liberalized. High price of oil
among with technological development has been
encouraging the recently modernized suppliers to launch
programs to find better and alternative ways to produce
electric energy. Governments and the European Union
have been eager to fund these programs, as they serve
both the technology and the environment.
A combined heat and power (CHP) plant utilizes its
waste heat in electricity generation. The process can
exploit fossil fuels, renewable energy or nuclear reaction.
The electricity producing efficiency in large, modern
condensing power plants is in the range of 40 % and the
efficiency in back pressure CHP plants up to 90 %.
Hence, a CHP plant can achieve savings of even 55% in
fuel energy consumed, when compared to the same
amount of power and heat produced in separate systems.
For politics, a CHP plant using biomass as a fuel is a
perfect response.
To best serve the environment, politics and industry,
there should be small CHP plants, which produce only
few MW of total energy, scattered around, rather than one
huge plant nearby a big city or a massive factory. But
built in a conventional manner, a small power CHP
system is an installation of very expensive kind. The
conventional manner means that the turbine and the
generator are separate systems and divided off from each
other by an axle seal, as illustrated in Fig. 1. This causes
leaks and therefore the system needs a whole water
supply unit to maintain the desired water level. Such a
unit includes a water tank and a pump and is packed with
complex automation system, which is needed e.g. to
control the water level.
Fig. 1. Conventional condensing power plant turbo-generator structure
with the turbine and the generator divided off from each other.
Fig. 1 illustrates the transmission between the turbine
and the generator, although it is not a necessary part of
the installation. There can also be the turbine and the
generator mounted in the very same shaft, but there must
be a seal between them. Obviously this cannot solve the
problem of leaks. With transmission, the speed of the
generator can be set as desired and all but any machine
type, but almost always a synchronous machine, can be
selected. On the other hand, the transmission has its own
power loss and therefore the overall efficiency suffers a
slight drop.
The problem of leaks can be solved by using a
hermetically sealed turbo-generator, in which the steam
flows also through the generator and acts simultaneously
as a cooling medium. The structure, as illustrated in Fig.
2, is very simple and contains no axle seals, which always
cause leaks.
Fig. 2. Hermetically sealed turbo-generator structure with steam flowing
through the air-gap of the generator.
With a hermetically sealed turbo-generator, no water
supply unit is needed and the plant is smaller, cheaper
and more reliable. Its control systems can be simpler,
when the water level does not need to be controlled. But
this sort of a structure sets substantially higher demands
for the generator – especially its insulation and thermal
design.
II. OVERVIEW OF THE GENERATOR
In this case the generator, the power of which is one
megawatt, is attached to the very same shaft with the
turbine. Therefore, its rotational speed is mainly
determined by the turbine, which, in order to be efficient
at this power range, needs a rotational speed of over
10000 rpm. Hence, the electrical generator has to be a
medium-speed one. The stator voltage of the 1 MW
generator is set to 690 V, which allows it to be driven
with a conventional frequency converter.
Permanent magnet synchronous machine offers the
best efficiency for such an application [2]. On the other
hand, as a structure it is a very challenging and expensive
one. According to [2], a slitted solid-rotor induction
machine with copper end rings is well suited for medium-
speed operation. This machine type has the same kind of
stator construction as a permanent magnet synchronous
machine has. The rotor, on the other hand, is made of the
very same piece of metal, including no expensive
magnets with supportive structures, which are somewhat
complex and difficult to assemble. Solid-rotor
construction is very robust, inexpensive and easy to
manufacture and therefore a viable solution to a small
power turbo-generator.
Naturally, the induction machine must be magnetized
before it can work as a generator. The magnetization can
be executed by the frequency converter installed between
the generator and the electricity network. The electric
drive does not actually differ from the conventional
inverter-fed drives used widely in industry. Only now, the
energy of rotational motion is converted to electricity.
It has been discovered that by installing a low-pass
filter, a passive LC-circuit, between the frequency
converter and the medium-speed solid-rotor induction
machine, rotor losses can be reduced [3]. Among with
this efficiency enhancing fact, the low-pass filter slows
down the fast voltage surges in the stator windings. This
prevents partial discharges in insulation system.
III. STEAM-RESISTANT INSULATION SYSTEM
One of the key elements in a hermetically sealed
turbo-generator is the insulation system. It must be
constructed from such materials, which are resistant to
hydrolysis in the given temperature. The low-pressure
turbine lowers the temperature and the pressure of the
steam. Inside the generator, the pressure is quite near the
atmospheric pressure and the maximum temperature is
supposed to be 115 ºC. This temperature in the condenser
is still suitable for district heating applications, which
makes the efficiency of the power plant high. The
temperature and the pressure are the parameters of
turbine design and are no further discussed in this paper.
But they set the demands for the insulation system.
A. Overview and materials
The generator should preferably have inexpensive
random-wound windings. If form-wound windings are
used, more room is needed in the end-winding area and
the generator has to be longer in the axial direction. This
increase in length makes it more prone to vibrations and
therefore less reliable. Furthermore, the form-wound
winding construction is notably more expensive. The
structure of an insulation system in a random-wound
machine is illustrated in Fig. 3.
Fig. 3. Structure of an insulation system in random-wound low-voltage
machine.
The most important part of an insulation system is the
groundwall insulation. It alone should be able to
withstand the whole electrical stress between stator
voltage and ground, and prevent short-circuits to happen
between conductors and stator core. Phase insulation
prevents different phases from short-circuiting with each
other in the end-winding area. These two are usually
made of the same material. In stator slot, groundwall
insulation can be wrapped so that it acts also as phase
insulation. This can be observed in Fig. 3.
Normally, the groundwall insulation is made of
synthetic polymers, such as Nomex aramid paper, Kapton
polyimide film or Mylar polyethylene-terephtalate (PET)
film (all trademarks of DuPont), or of combinations of
them. Kapton tolerates very high temperatures and has
good mechanical and dielectric properties. However, it
includes imide functional groups, which degrade, when
exposed to water at high temperature [4]. Mylar has
excellent mechanical properties: it is a tough, but still
flexible material. But Mylar (or any other PET or
polyester film) contains ester functional groups, which
are prone to hydrolysis. Nomex can tolerate high
temperatures and its chemical structure does not include
functional groups prone to hydrolysis, such as ester or
imide groups. Nomex has good dielectric properties,
excellent thermal stability and respectable resistance to
chemicals and moisture. As a downside, it has quite
mediocre mechanical properties: it may rip, if handled
without care during the coil manufacturing process.
The impregnating resin usually has fine dielectric
properties. Nevertheless, it has more mechanical than
electrical purpose. The magnetic field formed by the
stator current creates an oscillating force, the frequency
of which is twice the frequency of the stator current [5].
This oscillation can bend or twist or, in the worst case,
crack the coils, if the stator slot is not thoroughly filled by
the resin. The motion of coils in the slot can tear the
groundwall insulation and cause a failure. Therefore, it is
very important that the steam cannot dissolve the resin
away from the slot. Another purpose of the resin is to
give mechanical support and shield in the end-winding
area.
The impregnating resin is normally either polyester- or
epoxy-based. Polyester resins are widely used in low-
voltage machines because of their low price, high
temperature class, sufficient mechanical properties and
ease of handling in the manufacturing process. Moreover,
polyester resins have low viscosity, which enables the
resin to penetrate the stator slots easier. However,
polyester resins include ester functional groups, which
cannot tolerate water and high temperature
simultaneously, as was mentioned earlier. When the
environment, in which the machine is to operate gets
harsher, epoxy resins are favoured. They have good
mechanical properties and excellent resistance to
moisture and chemicals, but are more expensive than
polyesters.
The turn insulation prevents short-circuits to happen
between different turns. At the same time, the turn
insulation must have good mechanical characteristics.
When the windings are manufactured, the coils are bent
and stretched and constantly in touch with sharp edges.
The turn insulation must also tolerate different solvents,
which are used in the impregnation process.
Typical materials used in turn insulation are
polyesters, polyester-imides and polyamide-imides. They
are resins, which are cast on the wire. As their names
imply, they include either ester or imide functional
groups and, therefore, their steam-resistivity can be
questioned. Turn insulation can also be made of Kapton
or Nomex, the properties of which were discussed earlier.
They are wrapped on the wire like tape. The structure,
especially when made of Nomex, is not mechanically
strong. In the case of Nomex, it can be used only in rare
cases of very thick wire diameters. The suitable wire
insulator for this purpose would be polyether-etherketone,
PEEK. It has good mechanical and thermal properties and
it can resist hydrolysis in the temperatures up to 250 ºC
[6]. However, PEEK is commercially hardly if at all
available. Nevertheless, the price of PEEK is somewhat
astronomical compared to other turn insulators mentioned
here.
Fluoropolymers, such as FEP (fluorinated ethylene
prophylene) and PTFE (polytetrafluoroethylene), can
tolerate very high temperatures and have excellent
mechanical and chemical properties. Furthermore,
fluoropolymers have no tendency to absorb water and,
therefore, they have excellent resistance to hydrolysis. As
a downside, magnet wires insulated with fluoropolymers
have a dielectric strength of only one fourth of that of
polyester-imide-polyamide-imide-insulated magnet wire
of the same size. This has to be taken into account in
machine design.
B. Test methods
Insulation systems can be tested using so called
accelerated aging tests. In such tests, the stress is
increased above the normal operating level, which will
lead to failure in considerably shorter time, than would in
normal use. Between the lifetime, L, of the insulation
system and the prevailing temperature, T, there is a
correlation
B
L Ae T (1)
where A and B are constants. Equation (1) refers to that
thermal deterioration of organic insulating material is
because of the changes in its chemical structure [7].
Equation (1) is known as Arrhenius chemical
deterioration rate equation and it can be approximated so
that the lifetime decreases to half, when the temperature
rises 10 ºC.
The tests were carried out using small-scale models,
known as “motorettes”. Two separate testing series were
carried out. In the first series, the temperature of steam
was 90 ºC. After the test it was discovered that proposed
turn insulation was not available, since PEEK-insulated
magnet wire was pulled out of the market. At the same
time, there was a need to rise the temperature of steam to
115 ºC. Therefore, another testing series was needed. In
the second testing series, magnet wires were tested apart
from insulation systems as well.
The motorettes were built according to IEEE standard
test procedure [8]. The specimens were sunk in hot water
for eight days. The temperature of water was in the first
series 130 ºC and in the second series 150 ºC. The time
and temperature were chosen according to equation (1)
and instructions in [8]. After the water exposure in the
first testing series, the specimens were attached to a
vibrating bench, which imitates the vibrations in actual
motor caused by the alternative current. The amplitude of
the vibration was 0.1 mm and the frequency was 50 Hz.
This was omitted in the second series, because it had only
a slight effect on the insulation system and was difficult
to organize.
After each test and two times during the water Fig. 4. Polyester resin covered with epoxy potting resin after the
exposure to water, the temperature of 130 ºC. Note a huge crack in the
exposure, the motorettes were analyzed. At first, the resin layer.
motorettes were thoroughly investigated in order to find
any possible cracks or breaks or places, where the resin Nomex aramid paper and single-component epoxy
was missing. The groundwall insulation was tested by resin survived both the testing series. Nomex was able to
applying a 2700 V DC-voltage (maximum with our hold the electrical stress even when the resin had been
equipment) to both coils of the motorette, while the badly damaged, for instance in the case illustrated in Fig.
framework was kept at ground potential. The phase 4. The single-component epoxy resin was able to create a
insulation was tested by applying the same voltage to one thick layer in the end-winding area. This can be seen in
coil while keeping the other grounded. The voltage stress Fig. 5. Two-component epoxy resin survived the tests at
was kept up for one minute. Magnet wires were analyzed 130 ºC, but it was not tested at 150 ºC.
with a microscope.
Nomex aramid paper and a polyester membrane were
tested as groundwall insulation. Kapton polyimide, FEP
and PTFE fluoropolymers and polyester-imide and
polyamide-imide were tested as wire insulation. Single-
component polyester resin was tested both alone and
covered with two-component epoxy potting resin. Both
single- and two-component epoxy impregnating resins
were tested as well. The product names of the resins used
in tests are listed in Table I.

TABLE I. PRODUCT NAMES AND MANUFACTURERS (IN PARENTHESES)

OF THE RESINS USED IN TESTS.
Polyester resin CC-1105
(J. C. Dolph Company) Fig. 5. Motorette wound with polyester-imide- and polyamide-imide-
insulated magnet wire and impregnated with single-component epoxy
Epoxy potting resin Ultifil 2004 TC
resin after the water exposure at 150 ºC. Note thick layer of resin. Also
(AEV) note damages in turn insulation underneath the resin layer: Bright spots
in the coil are bare copper. From these spots the turn insulation has
Single-component Epoxylite 578EB disappeared.
epoxy resin (Altana Chemical)

Two-component epoxy EPR 162 Polyester-imide- and polyamide-imide turn insulation

resin (Bakelite AG)
C. Test results
The first testing series showed severe damage in
polyester resin and in polyester film used in groundwall
insulation. Polyester obviously cannot survive in steam.
The effort to cover the polyester resin with epoxy potting
resin failed as well, as can be seen in Fig. 4. This
insulation system was badly damaged after vibration test,
though it could not tolerate the steam either. Kapton, used
as turn insulation, also damaged in hot water of 130 ºC,
not as badly as polyester though.
was damaged badly at 150 ºC. It came off from the
copper conductor at most parts. When used in insulation
system, the wire was damaged, although the resin layer
on top of it seemed to be still intact. This can be observed
in Fig. 5. At the same temperature, fluoropolymers did
not suffer any damage at all. Of their steam-resistance,
there was no question. PEEK was not tested, since its
properties were already known. The proposed steam-
resistant insulation system at rated temperature of 115 ºC
is summarized in Table II.
TABLE II. STEAM-RESISTANT INSULATION SYSTEM.
Turn insulation FEP or PTFE
Groundwall insulation Nomex
Phase insulation Nomex
Impregnating resin Single-component epoxy resin
 The insulation system in Table II is notably more
expensive, than the one used in conventional low-voltage
machines. The price of the groundwall and the phase
insulation will not increase, while Nomex is also used in
conventional machines. On the other hand, PEEK-
insulated magnet wire is over thirteen times and FEP-
insulated magnet wire approximately 7-8 times more
expensive than polyester-imide- and polyamide-imide-
insulated magnet wire. Single-component epoxy resin
costs approximately one and a half times that of polyester
resin. Among with cost of pure material, epoxy resins are
also more expensive to use than polyester resins.
However, the increased cost of the insulation system will
hardly play a significant role in total expenses of the
power plant.
IV. THERMAL DESIGN
In electrical machines, the design of heat transfer is of
equal importance as the electromagnetic design of the
machine, since the thermal rise of the machine eventually
decides the output power of the machine. As a matter of
fact, the command of heat and mass transfer in an electric
machine is far more difficult and complicated than the
conventional electromagnetic design of an electric
machine.
The problem of temperature rise is twofold: first, in
most motors, adequate heat removal is ensured with the
thermal convection of air, thermal conduction through the
fastening of the machine, and thermal radiation. In the
case of a hermetically sealed turbo-generator the cooling
of the electric machine differs considerably from
conventional cooling solutions. This is mainly due to the
hermetic structure, which does not allow the use of an
additional air cooling and, therefore, the cooling fluid
must be the process fluid, i.e. in the case of a steam
process the cooling fluid is the process steam. The use of
steam as a cooling fluid sets requirements for the
insulation system of the machine as described earlier.
Furthermore, the conventional machine structure used in
The cooling of the stator back is boosted by using a water
cooled frame. The flow of the cooling fluid in the interior
parts of the hermetically sealed electric machine is
illustrated in Fig. 6.
Fig. 6. The structure of the hermetically sealed electric machine and the
flow path of the cooling fluid.
In order to ensure that the temperatures at different
parts of the machine do not exceed the temperature limits
set by the insulation system, a thermal resistance network
-based thermal analysis was performed. In the thermal
network model, the axial length of the machine was
divided into two parts. The convection coefficients as
well as the losses due to the cooling fluid friction were
calculated using analytical equations. The main equations
as well as the structure of the thermal model used are
found in [9]. The electromagnetic losses of the machine
were calculated using two dimensional finite element
analysis. A special cooling matrix was utilized to model
the heating of the cooling fluid [10].
The thermal analysis was performed at the nominal
operation point of the generator, i.e. the rotational speed
of the rotor was 14000 rpm. The temperature of the
process steam entering the generator was 74 qC. The
thermal model used contains 25 nodes and its structure is
shown in Fig. 7.
Ta Ta Ta Ta
Ta
Rfr5+R2 Rfr1+R4
Frame
Rfr1+R4 Rfr5+R2

Ta
medium and high-speed applications where the stator Rfr4+R1
2
Rfr3+Rfr4
1
Rfr3 Rfr3
14
Rfr3+Rfr4
15
Rfr4+R1
Rfr2+Rco1+Rsy1 Rfr2+Rco1+Rsy1
stack is divided into two parts and the space between Rfr6+R3 Rfr6+R3

3 Yoke Yoke 16
stator sections is used as a radial cooling duct cannot be Rsy2
Rsy3
Rsy5 Rsy5
Rsy3
Rsy2

used anymore. End-winding

space 12
End-winding
24 space
Rsy4+R6 Rsy4 Rsy4 Rsy4+R6
When the machine is cooled by means of the process Rst1 Rst1
Rsew2+R9 Rst2 Rsw1 Winding Winding Rsw1 Rst2 Rsew2+R9
steam, the cooling fluid is blown through the frame to the 4 5 18 17
Teeth Teeth
upper end-winding space on the right side of the machine. Rst1+R7
Rsw2+ Rsew1
Rsw3
Rsw2 Rsw2
Rsw3
Rsw2+ Rsew1
Rst1+R7

End-winding 6 19 End-winding
If the steam penetrating the air gap is dry, the steam 11 Air-gap Air-gap 23
Rsew2+R10 Rsew2+R10
superheats while absorbing heat from the machine and Rrer1+R12 Rrer3
Rotor-end Rrc1+R11
Rotor Rotor
Rrc1+R11 Rotor-end
Rrer3 Rrer1+R12

the temperature rises rapidly. In order to intensify the Rrer2

9
Rrc3
7 surface surface 20
Rrc3
Rrc2 Rrer5
22

Rrer2
Rrer5 Rrc2 Rrc5 Rrc5
cooling of the right coil ends and to keep the temperature End-winding 13
Rrc4 Rrc4 Rrc4 Rrc4
25 End-winding
space space
moderate, the inlet steam can be humidified. In that case Rrer4+R13 Rer4 Rer4 Rrer4+R13

the cooling steam absorbs heat effectively from the outer Rry1 Rry1
Rry3 Rry3
surface of the coil ends as a result of the vaporization of 8 Rotor yoke Rotor yoke 21

the water drops. A blower is needed on the left side of the Rry2 Rry5
Rry4 Rry4
Rry5 Rry2

machine to blow the process steam through the air-gap to Rry4+R14 Rry4+R14

the lower end-winding space. The steam will condense Rsh4+R16

Rsh3+R15

Rsh2+Rsh4
Rsh1
Rsh2+Rsh4
Rsh3+R15
Rsh4+R16

after the blower and therefore the coil ends on the left Ta
10 Shaft
Ta

side of the machine are partially immersed into the water. Fig. 7. The thermal resistance network model used in the thermal
Finally, the water is removed from the interior parts of analysis.
the machine through the hole on the left side of the frame.
 The thermal analysis revealed that that maximum
temperature is 116.2 qC and it occurs at the coil ends on
the right side of the machine. Because the maximum
temperature occurs at the centre point of the coil end, the
temperature at the surface of the coil end is somewhat
lower, it can be concluded that insulation system
presented in the Table II is valid for this application.
V. CONCLUSIONS
In low power CHP production the price of the plant
has to be moderate. By using a medium-speed generator
directly attached to the turbine shaft no gear is needed
and a lot of material is saved in the construction. If the
turbo-generator is built as a hermetical unit no water
supply unit is needed. A hermetical turbo-generator has
also other significant advantages over the one with the
turbine and the generator divided off from each other.
Decentralized CHP plants of small output power can have
simpler structure, less complex automation systems and
easier controlling methods. All put together, they are
more reliable and less expensive to build.
One major challenge is overcome when discovered
that a steam-resistant insulation system can be built using
available insulating materials. Such a system is notably
more expensive compared with insulation systems used
in conventional machines. Nevertheless, this is a very low
price to pay regarding the whole plant.
The thermal design of the steam cooled turbo
generator is challenging and somewhat complex, but can
be done using for example thermal resistance networks.
A hermetically sealed turbo-generator is without a
doubt one step up the ladder towards the cost-effective
exploitation of renewable energy sources. Yet, will the
world go on with fossil fuels. But all the innovations of
this kind will set more hopes that perhaps there will be a
day when a consumer chooses electricity produced from
renewable energy over electricity from fossil fuels not
because of the environment, but because of the cost.
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