The 19th International Symposium on High Voltage Engineering, Pilsen, Czech Republic, August, 23 – 28, 2015

ENHANCED CALCULATION AND DIMENSIONING OF OUTER

CORONA PROTECTION SYSTEMS IN LARGE ROTATING MACHINES
1* 2 1
G. Schmidt , A. Litinsky and A. Staubach
1
Siemens AG, Rheinstr. 100, 45478 Muelheim an der Ruhr, Germany
2
University of Duisburg-Essen, ETS, Bismarckstr. 81, 47057 Duisburg, Germany
*Email: guido.schmidt@siemens.com

Abstract:
The primary components of electrical field grading systems in modern large rotating
machines and especially in large turbo generators are applied to cope with locally
increased electrical and thermal stresses affecting the electrical insulation system. In
terms of future development and improvement of efficient insulation systems with a higher
output to volume ratio adequate tools and techniques are necessary for dimensioning the
electrical field grading system in a time and cost saving manner.
Numerical calculation models based on the Finite Element Method (FEM) allow a
theoretical approach to design electrical field grading systems before approving the
functionality in real test setups. Additionally these calculation models help to get an in-
depth understanding of specific theoretical aspects which are not possible to be
measured physically or calculated with analytical equations at all.
In this essay highly specialized FEM models are introduced which allow calculations of
extensively structured OCP systems. Especially the results of investigations of electrical
parameters (i.e. potential, field distribution, resistive losses) depending on varying OCP
resistivity are discussed. Based on this it will be illuminated if and how an optimum OCP
resistance could be defined at all based on the major influencing parameters.

1 INTRODUCTION components. It is assumed that especially air

The main insulation system of large rotating
machines applied at high rated voltages up to 27kV
is an arrangement of fundamental subcomponents.
Here the main insulation layer is embedded in the
multilayer structure build up by the field grading
components inner corona protection (ICP), outer
corona protection (OCP) and end corona
protection (ECP). These components have to cope
with individual service relevant challenges. The
function of the OCP system is to connect the
ground potential to the main insulation surface via
the laminated stator core and to control the
electrical field strength distribution in the main
insulation in the slot area. Here the OCP material
itself is mainly characterized by its nominal
resistivity which constitutes the overall resistance
of the complete OCP system depending on a
complex insulation system geometry and structure.
Any variation of the resistivity, i.e. due to
manufacturing process parameters or service
related global ageing or local degradation effects,
leads to a change of the overall OCP system
behaviour or the localized OCP integrity. The
assessment of such variations is closely related to
the still open discussions about optimum OCP
resistivity on rotating machine insulation systems.
The continuously rising requirements on efficiency
for rotating machines demand a simultaneous
quality and resistivity improvement of insulating
systems. The wish to control multiple electrical and
mechanical influences raised the overall
complexity of insulating systems including their
cooled rotating machines are exposed to higher
thermal, electrical and mechanical stress due to
less efficient type of cooling. These machines are
usually manufactured in a GVPI (Global Vacuum
Pressure Impregnation) process, which requires
special aligned solutions to handle the stress types
stated above. In the last years an increased
amount of issues regarding multiple kinds of
insulation system deterioration could be observed
on air cooled machines respectively turbine
generators. Most of the published literature
highlights the increased thermal and electrical
stresses which could lead to severe PD related
degradation as a reason for such observations [1].
2 GVPI STATOR INSULATION SYSTEM
The insulation systems of large rotating machines
and especially of large turbo generators which are
manufactured according to the GVPI process and
that are operated at high electrical, mechanical and
thermal stresses require multi-layered field grading
components and designs with high complexity. The
actual electrical highly stressed main insulation
sleeve consists of resin impregnated wrapped fine
mica tape layers and is embedded by the ICP (on
high electrical potential) and the OCP (on ground
potential). In detail the high electrical potential is
distributed over the full length of ICP by a copper
strip, which is connected directly to the copper
Roebel bar in a certain location. Both the ICP and
the OCP in combination provide a preferably
homogenous electrical field.
2.1 Corona Protection System OCP and ECP
Many air cooled machines are manufactured in a
cost- and assembly-effective GVPI process. After
the curing cycle the stator converts to an overall
compact and solid structure. Especially large
generator stators have to be assessed in terms of
thermo-mechanical forces under service conditions
i.e. shear forces in the fixed stator bars. This fact
demands customized solutions for a GVPI
insulation sleeve to prevent possible damages
which could lead to serious insulation damages.
Therefore all large Siemens generators are
equipped with a so called double layer OCP
system. In this design the relevant detail is a
insulating layer of mica splitting tape which is
embedded between two wrapped OCP layers
(inner OCP and outer OCP) (Figure 1) [2].
Figure 1: GVPI stator bar insulation system
This construction defines a predetermined area
which could allow certain kind of relative
movement of the bar without damaging the main
insulation layer due to delamination from the
electrode layers. The inner layer of the double
layer OCP system is the active electrode on
ground potential to homogenize the electrical field
inside the main insulation sleeve. The outer
conductive layer directly contacts the laminated
stator core. For a proper electrical function the
ground potential from the stator core is transported
to the inner layer by an interwoven conductive tape
stripe, which alternately contacts both conductive
layers of the double-OCP system on one broad
side of the stator bar (Figure 1 and Figure 2).
Figure 2: Taping processes of GVPI OCP system
In the slot exit area on both ends of the laminated
stator core the bars drop out of the core and bend
into the involute portion in end winding baskets.
The OCP layers end right after the slot exit. Hence
the connection to the grounded core sheets is
restricted. To prevent any surface discharge
activity at the OCP ends these are cover and
contacted by the end corona protection (ECP) [3].
The ECP controls the electrical potential raise from
ground to nearly rated high potential. Today’s ECP
materials show a complex dependency of the ECP
resistance of the local field strength and of the
local temperature [4]. Out of this it directly follows
that the OCP and the ECP constitute a field
grading system where specific electrical and
thermal behaviors influence each other’s. In
consequence the assessment of the overall
functionality has to be performed with the analysis
especially of the possible interactions between
OCP and ECP.
2.2 OCP Resistance
The resistance of the OCP in principle is a
commonly used parameter for multiple discussions
that deal with electrical functionality or degradation
and damaging issues [1]. Here the so called
square resistance often has to serve as a popular
simplification of an in fact complex structure of
interactions between multiple resistance influence
factors [5][6]. The question after the “optimum OCP
resistance” is still not answered. There are
discussions ongoing but such searches for proper
OCP resistance values can hardly be answered if
the relevant influencing factors are not combined to
an overall sight [5].
The resistance value or range for OCP material
(i.e. tape) is obviously depending on the specific
design and with consideration of all relevant
boundary conditions. The consequences of
lowered resistance could be electrical losses
through parasitic currents. Heightened resistances
could lead to insufficient field grading and therefore
to discharges, which have potential to damage the
insulation [7]. In reality the target value for the
resistance generally varies depending on the
manufacturer and type of the rotating machine. For
example, most of the tapes on the market
developed for application as corona protection
material show a strong dependency of the
resistivity on epoxy resin content results from
impregnation and curing process [5].
As explained in this essay the overall OCP system
could be a complex composition of conductive
structures. Therefore it is more plausible to not
discuss an OCP resistance but to investigate the
OCP resistivity as a strongly material related
parameter. Then it also would be possible to
discuss even local parameters like direction
dependency of the resistivity [5].
3 IMPROVED FEM CALCULATIONS Especially the areas outside of generator stator
core are very complex structures. The presence of
Assuming the mentioned facts the consequences specific geometrical and electrical components like
of resistivity deviations for the multi-layered the stepped iron as local distribution of the ground
insulation system will be investigated. The potential results in challenging FEM model
geometrical complexity of the whole structure can creations (Figure 4).
hardly be approximated with one equivalent circuit.
Here the implementation of a numerical method
such as FEM (Finite Element Method) has proved OCP
its efficiency [2][5]. The previous attempt to
approach the electrical characteristics of generator
stator bars resulted in two initial FEM models of the
straight portion and were realized based on certain
Siemens generator designs. The basic applicability
of FEM as well as the dependency between
resistivity and insulation system design has been
demonstrated successfully [5].

But the existing models were limited to the OCP

material as the only resistive component. It was
already described that the overall corona
protection system consists of OCP and also of
ECP components. Hence it is essential to extend
the existing models by implementing the relevant
ECP components. Due to material specific non-
linear properties of the ECP material it shows a
field strength and also temperature dependent
behaviour. This specific aspect was deeply
discussed in [4] and led to calculation results by
performing extensive iterative calculations which
customized the resistivity of ECP material
depending on local field strength distribution and
heat generation.
laminated
protection
core
layer
Figure 4: Slot exit area at core ends
Both improved models base on a specific and real
Siemens generator design. The model of the
straight part of the stator bar is a short section of a
several meters long bar (Figure 5). The transparent
volumes represent the stator core sections
separated by ventilation ducts.

3.1 Extended FEM Models

The areas of interest regarding complex

interactions between OCP resistivity and stator
design are the straight part of the stator bars in the
slot and the slot exit area where the ECP is located
(see Figure 3: yellow marks).

Figure 3: End winding basket of GVPI generator

stator Figure 5: Section of generator stator straight part
embedded in stator core sections
The FEM model of the slot exit area is shown in
Figure 6. It underlines the complex geometry
where no symmetries could be used to reduce
meshing and calculation effort. The model is
shown here without the red protection layer to
better visualize the relative positions of OCP and
contacting ECP.
OCP
ECP
stator core
Figure 6: FEM model of stator bar in slot exit area
Figure 7 gives an impression of FEM calculation
status after the meshing process.
Figure 7: Meshed FEM model of stator bar in slot
exit area
The completed model of this slot area contains
approx. 100.000 elements. This number is the
result of multiple meshing trials to determine the
minimum density at hence number of finite
elements. Even though this could be assessed as
a relatively rough meshing it definitely provided
results with sufficient resolution. The reason for
minimization of finite elements and connecting
nodes is founded in the necessity of multiple
iteration and calculation steps to generate
plausible electrical and thermal results.
Furthermore it is still a major challenge to realize a
computable FEM model where thick insulation
layers of relevant length are covered by very thin
layers which are the area on interest.
3.2 Calculation Results
The presentation on the calculation results
concentrates on the qualitative assessment of
electrical parameters like electrical potential,
electrical field strength and on the temperature
distributions. With this the capability of the
improved FEM models should be pointed out. The
investigation and discussion of quantitative results
regarding optimization of OCP resistivity has to be
realized in follow up essays. Therefore the calcu-
lations were performed with three different OCP
resistivities: low, medium, high.
3.2.1 Straight Part: Mica Interlayer in OCP
As the mica splitting layer as a mechanical slip
layer has the character of a very thin insulating
material it could be relevant in terms of feasible
OCP resistivity values to assess the electrical
stress in that layer. Under normal resistivity
conditions this area is expected to be nearly free of
electrical stress. In principle it is supposable that
the specific geometric structure of the double layer
OCP could lead to locally heightened electrical
field strength stress in the mica splitting layer. But
only the FEM calculation could lead here to
concrete evaluation of local electrical stress.
Figure 8 shows the straight part bar section and on
the right the extracted mica splitting layer which is
normally embedded between the inner and outer
OCP layers.
Figure 8: Meshed FEM model of stator bar straight
part and extracted mica splitting interlayer with
result path and coordinates cross
The red line demonstrates the path around the bar
as origin of the electrical field strength values. The
angle φ displays the direction of rotation starting
at 0° to recognize the position after transformation
into polar coordinates (Figure 9).

(a): low resistivity

Figure 9: Electrical field strength in mica splitting

layer depending on OCP resistivity

It is obvious that the electrical field strength follows

the asymmetric bar design where the interweaved
layer only is located on the one broad side. On the
other side the electrical field strength could reach
high values due the fact that the electrical potential
has to be carried around half of the bar.

3.2.2 Slot Exit Area

The field strength dependent characteristic of ECP
allows a targeted manipulation of electrical
(b): medium resistivity
potential in the slot exit area close to the end of the
grounded core. The ECP is connected to the
laminated stepped core on ground potential via the
resistive OCP. That means that the OCP feeds the
ECP with current. This clarifies the assumption that
both field grading components simply influence
each other. The range of this interaction depends
on the ratio of the OCP and ECP resistivity.
According to the straight part model only an FEM
calculation can clarify the special potential
distribution for example in the outer OCP layer.
Figure 10 shows these distributions for three OCP
resistivities (low, medium, high).

The simulation results show clearly that the high

electrical potential “moves” towards the laminated
stator core corresponding to the increase of OCP
resistivity. That means that the OCP behaves more
like an ECP if its resistivity is getting very high. So
it could be imagined that unexpected high OCP (c): high resistivity
resistivity could lead to localized heightened
electrical field strength on the surface of the OCP
followed by unacceptable and probably Figure 10: Electrical potential distribution in OCP
deteriorating surface discharges. and ECP areas depending on the resistivity of
OCP material
Figure 11 concentrates on the potential distribution
along the center of the upper narrow side of the
model bar. Here the transition area between OCP
and ECP is marked as dotted line. On the one
hand the increase of electrical potential with rising
OCP resistivity is obvious. On the other hand that
diagram clearly shows that the heightened OCP
resistivity impacts the function of the whole field
grading system. The common “potential overshoot”
of the ECP seems to move towards the core with
increasing OCP resistivity.
Figure 11: Electrical potential distribution on the
upper narrow side of the bar in the slot exit area
3.2.3 Temperature Distribution in OCP Layer
The results of the electrical parameters show that
resistivity conditions could influence the
functionality of the OCP ECP network. Of course
resistivity aspects could directly be translated into
conclusions for currents and hence into heat
generation results. Here the FEM allows a coupled
simulation of electrical and thermal influences
depending on the defined boundary conditions.
Figure 12: Temperature Distribution caused by
Ohmic losses in the ECP and OCP
In this first step it was possible to calculate a
volumetric heat generation rate caused by a proper
functioning of the ECP as well as the locally
heightened current flow between stator core and
ECP (Figure 12). This example shows exemplarily
the result for medium OCP resistivity. The
difference between low and high temperature in
this example result plot is several Kelvin. But it has
proved the model’s capability for heat generation
calculations, too.
4 CONCLUSIONS
The FEM has the potential to generate plausible
information about the insulation system of rotating
machines and especially large turbo generators.
With the successful implementation of the analysis
of interactions between OCP and ECP a
fundamental basis for further investigations of OCP
resistivity optimization is achieved.
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