Testing & maintenance of insulation

Unit-4: Testing & maintenance of Insulation Ghatal Govt.
Polytechnic
Testing & maintenance of Insulation

Introduction
The atom of a substance consists of central nucleus, surrounded by orbiting electrons. The
nucleus consists of protons and neutrons, each of which has a mass of about 1840 times the mass
of electron. Neutrons have no charge, while protons have positive charge equal in magnitude to
the negative charge on electron. The electrons are arranged in different shells and are moving
around the nucleus just similar to the planets around the sun. Each shell can contain only a certain
number of electrons. The electrons in the outermost shell are termed as valence electrons. The
electrons in the orbits nearest to the nucleus are tightly bound to the nucleus whereas the
valence electron are comparatively loosely bound to the nucleus. The valence electrons largely
determine the electrical properties of the atom or material.
In case of materials such as silver, copper etc., the valence electrons can be easily detached,
which will create a great mass of free electrons (or electron gas) drifting about through the space
between the atoms. Since each atom has lost an electron, it becomes a positive ion. The electron
gas is negatively charged. The electrostatic force between the positive ion and the electrons gas
holds the metallic bonding. The free electrons gas holds the material together. This type of
bonding is known as metallic bonding. The free electron can be given motion in a specific
direction by application of electric field and the current is achieved.
Metals are good conductor of electricity. In an insulating material the bonding is covalent or ionic.
In materials like rubber and plastic the bonding is covalent i.e., the valence electrons are shared
by adjacent atoms. Each valence shell of every atom appears to be filled. Consequently, there are
no free electrons drifting about and the possibility of current flow is almost zero. In insulating
materials like glass and procelain, the valence electrons are denoted by one atom and accepted
by the other to form a bond. In this case also there are no free electron and there is no possibility
of current flow. The resistivity of an insulating material is of order of 1012 ohm-meter.
QUALITIES OF INSULATING MATERIALS USED IN MACHINES
Insulating materials which, is used in machines should have following qualities:
(i) It must provide proper separation of machine parts or components, this must be available
even at high temperatures and the influence of humidity, dirt or corrosive chemical fumes.
(ii) The insulation should not get damaged due to mechanical vibrations etc. when the machine
is working.
(iii) The space occupied by the insulation should be very small or it should be thin, so that best
use of core and copper material can be made.
(iv) It should conduct the heat from machine parts for dissipation.
(v) It should not absorb moisture from surrounding.
(vi) It should not get damaged or punctured due to high voltage surges subjected on the supply
system.
Prepared by Sanjoy Pondit, Lecturer, Department of Electrical Engineering, Ghatal Govt. Polytechnic
Unit-4: Testing & maintenance of Insulation Ghatal Govt. Polytechnic
Classification of insulating materials as per I.S. 8504(part III) 1994:

Different insulating materials used in electrical machines and equipment are classified into
following categories depending upon their thermal stability as per I.S. 8504(part III) 1994. In the
table maximum operating temperature for each class of insulating material is given assuming
maximum ambient temperature of 40°C.
Sr. No. Class Insulating materials Uses Maximum
operating temp.
1. Y/O Cotton, silk, paper, press, Rarely used without 90°C
board vulcanized fibre, impregnation 90°C
wood, PVC, VIR etc.
without impregnating
substance.
2. A Cotton, silk, paper, press Leatheriod paper as slot 105°C
board, vulcanized fibre, insulation, cotton covered
wood etc. Impregnated wires impregnated in
in dielectric oil or varnish shellac varnish, spot wages
also some types of wire etc.
enamel.
3. E Leatherised paper, Slot insulation, winding 120°C
polyviny lacetal (PVA) wires. insulation,
enamel for super insulating mouldings with
enamelled conductors, epoxy resin in case of
epoxy resins, cotton chokes, CT etc.
fabrics, and paper
laminates, mouldings
with cellulose fibre
4. B Glass fibre, asbestos, Slot liners, phase 130°C
mica, build up mica, mica separators etc. Insulating
laminations etc. with tape, binding cord etc
bonding substances like polyster enamel
sheline, bituminous conductors
compounde, epoxy resins
etc.
5. F Glass fibre, asbestos, Slot liners, separators, 155°C
mica, varnished glass tapes, cards etc.
fibre textile, builtup mica polyesterimide enamel or
etc. with bonding fibre glass braided and
substances like epoxy varnished with poly
and silicon alkyl resins. urethane wires for coils.
6. H Same materials as for Slot liners, insulation 180°C
class F with suitable tapers. separators,
binding materials i.e., conductors, insulation
silicon based sleeves etc. Sleeves etc.
glass fabric, flexible

micanite with suitable
resina or polyamide films
glass fabric.
7. C Mica, porcelain, ceramics Same as class H, also Above 180°C
Same as class H. also insulating material is ovens
insulating glass, quartz, etc.
asbestos, treated
material is ovens etc.
glass fibre or treated
asbestos with inorganic
binders such as glass or
cement and silicon resins,
slate, marble.
EFFECT OF TEMPERATURE AND MOISTURE ON INSULATION RESISTANCE

The insulating material have no free electrons for conduction of current. Hence, if a potential
difference is applied across it, there is no current flow through the insulator or if at all any current
flows through it, it will be very very small in magnitude. When such a material is heated up and
acquires higher and higher temperature very few electrons are successful to break through the
bond and become free, which will be available for conduction of current when sufficient potential
difference is applied across it. If the potential difference is maintained constant and temperature
of insulating material is increased higher and higher, more and more current flows through it.
Hence, when the temperature of any insulating material increases, it decreases the insulating
power of the material. In some cases when the temperature exceeds the limit, the insulating
material starts behaving like conducting material.
Moisture also effect the insulating material. When insulating material comes in contact with
moisture then its insulating strength decreases. Insulation resistance of the insulating material
also decreases when it comes in contact with moisture.
REASONS FOR DETERIORATION OF INSULATION RESISTANCE
Insulation resistance of insulating material changes with the change in following factors.
(i) Temperature
(ii) Atmosphere
(iii) Age
(iv) Applied voltage
(v) Dielectric strength
(vi) Tracking
(vii) Oxidation
(viii) Impurities
(ix) Light
(i) Temperature: If the temperature of any insulating material increases, then its insulation
resistance decreases.
Effect of temperature Insulating resistance
(ii) Atmosphere: Presence of moisture/humidity in the air affects the resistance of insulating
material. Insulating resistance of the insulating material weakens when comes in contact with
atmosphere, like the insulators present in the overhead lines. Moisture present in the
atmosphere reduces the insulating resistance.
(iii) Age: Insulating resistance of the insulators weaken with the passage of time. Insulation
strength decreases due to following reasons:
(a) More load than the required capacity
(b) Oxidization
(c) Drying
(d) Many other reasons
Some materials such as porcelain, mica, only have their insulating strength for the longer time.
When paper, cellulose etc. got dried its insulation resistance destroyed. At high temperature,
they are converted into powdered form.
(iv) Applied voltage: Magnitude of applied voltage also affects the insulating strength. The
magnitude of insulating resistance is certainly decreases when measured by megger at 500 V,
1000 V, 2500 V, 5000 V respectively.
(v) Dielectric strength: Conducting material and equipment operates on a certain voltage. But if
they are operated on higher voltage then prescribed voltage, its insulating strength get
destroyed, which eventually damage the insulating quality of insulating material.
Let us take an example, if an insulating material is kept between the two conductors and increase
the voltage more than its capacity. This will cause insulating resistance puncture Voltage gradient
can be obtain by dividing the magnitude of voltage puncture with the diameter of the wire in
kV/mm. This breakdown strength is known as dielectric strength. That minimum voltage at which
insulating strength breaks down is known as breakdown voltage. This is measured in v/mm or
kV/mm.
(vi) Tracking: Due to breaking down, burning or melting of insulating material irregular holes are
produced in it. Now, even if minimum voltage is applied on it, the current will follow through
irregular path and then the solid material will lose its insulating strength, This is called tracking.
(vii) Oxidation: Resistivity of insulating material decreases as the material get oxidize. As the
temperature increases the material get oxidize rapidly, which reduces the resistivity.
(viii) Impurities: As impurity in the insulating material increase, the resistivity of the material
decrease.
(ix) Light: High intensity of light, decreases, the resistivity of insulating material Difference
between insulation resistance and earth resistance.
Insulation resistance is measured between conductor and earth. It is of the order of several
tens/thousands mega ohms or infinity for healthy insulation. It is measured by means of megger
(mega-ohm meter), with built-in DC generator. Earth resistance is measured for a earthed
metallic body or neutral point. It is measured by means of earth resistance tester. For good
effective earthing, the earth resistance should be of the order of 0.5 ohm.
FACTORS AFFECTING THE LIFE OF INSULATION

Insulations in large machines and equipments are expected to prove serviceable for periods of
20 years or more with a minimum maintenance. To perfect long life is exceedingly difficult
primarily because of the in ability to anticipate and control the corona activity, the effect of heat,
and other factors as enlisted below:
Sr. No. Operation Degradables
1. Processing materials Poor quality elements, damage to elements in preparation,

into usable forms misformulation, misorientations. mis-guaging, introduction
of contaminants. packaging, handling.
2. Processing materials Specifications and design errors, process distortion,
into coils introduction of contaminants, process problems in-
experienced and careless applicators.
3. Assembly of insulated Improper transportation and storage, componenta
coils in motors or improperly sized, product damage from winding.
other equipments. operations contaminations, excessive splicing
temperature, misuse of tool, destructive testing
4. Motor application Misapplication of motor (type, size, duty cycles, enclosure,
environments).
5. Motor operation Internal and external heat, mechanical forces, electrical
disturbances, corona phenomena. chemical atmospheres,
abrasive dust, water, (humidity) condensations.
Methods of measuring temperature of internal parts of windings/ machines

In general, for measuring the temperature of the windings of a machine, the resistance method
shall be applied. The embedded temperature detector (ETD) method shall be used for ac stator
windings of machines having a rated output of 5000 kW (or kVA) or more, unless otherwise
agreed.
For ac machines having a rated output below 5000 kW (or kVA) and above 200 kW (or kVA) the
resistance method shall be used, unless the ETD method is agreed.
For ac machines having a rated output of 200 kW (or kVA) or less the resistance method shall be
used, unless the superposition method is agreed.
For machines rated 600 kW (or kVA) or less, when the windings are non-uniform or severe
complications are involved in making the necessary connections, the temperature-rise may be
determined by means of thermometers (or non-embedded thermocouples).
For ac stator windings having only one coil-side per slot, the embedded detector method is not
recognized and the resistance method shall be used.
For checking the temperature of such windings in service, an embedded detector at the bottom
of the slot is of little value because it gives mainly the temperature of the iron core. A detector
placed between the coil and the wedge will follow the temperature of the winding much more
closely and is, therefore, better for check tests, although the temperature there may be rather
low. The relation between the temperature measured at that place and the temperature
measured by the resistance method should be determined by a temperature-rise test.
For windings of armatures having commutators and for field windings, except for field windings
in cylindrical rotors of synchronous machines, the resistance method and the thermometer
method are recognized. The resistance method is preferred.
For stationary field windings of dc machines having more than one layer the ETD method may
also be used.
(i) Determination of Temperature-Rise of Windings by the Resistance Method
Copper windings
The temperature-rise t2 – ta may be obtained from the ratio of the resistance by the formula:
𝑡2 + 235 𝑅2
=
𝑡𝑎 + 235 𝑅1
Where
t2 = temperature (°C) of the winding at the end of the test,
ta = temperature (°C) of coolant at the end of the test,
t1 = temperature (°C) of the winding (cold) at the moment of the initial resistance measurement,
R2 = resistance of the winding at the end of the test, and
R1 = resistance of the winding at temperature t1 (cold).
For practical purposes, the following alternative formula may be found convenient:
tr (Temperature-rise) = t2 – ta
𝑅2 − 𝑅1
= (235 + 𝑡1 ) + 𝑡1 − 𝑡𝑎
𝑅1
When the temperature of a winding is determined by resistance, the temperature of the winding
before the test, measured by thermometer, shall be practically that of the coolant.
Non-copper windings
For materials other than copper, replace the number 235 in the above formula with the reciprocal
of the temperature coefficient of resistance at 0°C of the material. For aluminium, unless
otherwise specified, the number 225 shall be used.
(ii) Determination of Temperature-Rise by the Embedded Temperature Detector (ETD) Method

When the ETD method is used, the detectors shall be suitably distributed throughout the
machine windings and the number of embedded detectors installed shall be not less than six.
All reasonable efforts, consistent with safety, shall be made to place the detectors at the various
points at which the highest temperatures are likely to occur, in such a manner that they are
effectively protected from contact with the primary coolant.
The highest reading of ETD elements shall be used to determine compliance with requirements
for temperature-rise or temperature limits.
If there are two or more coil-sides per slot the detectors shall be installed. If there is only one
coil-side per slot, or if it is desired to measure the end winding temperature, the recommended
methods of installation are given below, but in these cases, the ETD method of temperature
measurement is not recognized method for determining temperature-rise or temperature limits
in order to verify the compliance of the rating with this standard.
Two coil-sides per slot or more than two coil-sides per slot
When the winding has two coil-sides per slot or more than two coil-sides per slot, the
temperature detectors shall be located between the insulated coil-side within the slot in
positions at which the highest temperature are likely to occur.
One coil-side per slot
When the winding has one coil-side per slot, detectors that are embedded in the slots should be
located between the wedge and the outside of the winding insulation in positions at which the
highest temperature are likely to occur.
End winding
Where applicable, the temperature detectors should be located between two adjacent coil-sides
within the external range of the end windings in positions at which the highest temperatures are
likely to occur. The temperature sensing point of the temperature detector should be in close
contact with the surface of the coil-side and be adequately insulated against the coolant
influence.
(iii) Determination of Temperature-Rise by the Thermometer Method
The thermometer method is recognized in the cases in which neither the ETD method nor the
resistance method is applicable.
Use of the thermometer method is also recognized in the following cases:
a) When it is not practicable to determine the temperature-rise by the resistance method as for
example, with low resistance commutating coils and compensating windings and, in general in
the case of low resistance windings, especially when the resistance of joints and connections
forms a considerable proportion of the total resistance.
b) Single-layer windings, rotating or stationary.
c) The measurement of temperature-rise during routine tests on machines manufactured in large
quantities.
If the purchaser wishes to have a thermometer reading in addition to the values determined by
the resistance method or by the ETD method, the temperature-rise determined by thermometer,
when placed at the hottest accessible slot, shall be the subject of agreement between
manufacturer and purchaser, but shall not exceed:
65°C for Class A insulation of windings
80°C for Class E insulation of windings

90°C for Class B insulation of windings
115°C for Class F insulation of windings
140°C for Class H insulation of windings
Correction of Measurements Taken when the Machine is hot:
(i) The measurement of temperature after shutdown by the resistance method requires a quick
shut-down of the machine at the end of the temperature test. A carefully planned procedure and
an adequate number of people are required to obtain readings quickly enough to give reliable
data.
If the initial resistance reading is obtained within, the time interval indicated below, this reading
shall be accepted as the temperature measurement, and extrapolation of observed temperatures
to the instant of switching off the power is unnecessary.
a) When it is not practicable to determine the temperature-rise by the resistance method as for
example, with low resistance commutating coils and compensating windings and, in general in
the case of low resistance windings, especially when the resistance of joints and connections
forms a considerable proportion of the total resistance.
b) Single-layer windings, rotating or stationary.
c) The measurement of temperature-rise during routine tests on machines manufactured in large
quantities.
Rated Output (P) Time Delay After Switching Off Power
(kW)/(kVA) (s)
P ≤ 50 30
50 < P ≤ 200 90
200 < P ≤ 5000 120
5000 < P By agreement
(ii) If the initial resistance reading cannot be made in the required length of time, it shall be made
as soon as possible afterwards and additional resistance readings be taken at intervals of
approximately 1 minute until these readings have begun a distinct decline from their maximum
values. A curve of these readings shall be plotted as function of time and extrapolated to the time
delay specified in the above table for the rated output of the machine.
A semi-logarithmic plot is recommended where temperature is plotted on the logarithmic scale.
The value of temperature thus obtained shall be considered as the temperature at shut-down.
If successive measurements show increasing temperatures after shut-down, the highest value
shall be taken.
(iii) For machines with one coil-side per slot, the resistance method may be used if the machine
comes to a standstill within the time delay specified in the table above. If the machine takes
longer than 90s to come to rest after switching off the power, the superposition method may be
used if previously agreed between the manufacturer and the purchaser.
(iv) If the initial resistance reading cannot be made until after twice the time delay time specified
in (i), the method of (ii) shall only be used by agreement between the manufacturer and the
purchaser.
Properties of good transformer oil:
According to IS: 335-1983, new insulating oil which is used in transformer and other switchgear,
should have following properties.
(i) Appearance: New insulating oil should be clean, transparent and sediment free.
(ii) Density: Density of oil at 27°C should be 0.89 gm/cm³.
(iii) Kinematic viscosity: Kinematic viscosity at 27°C should be 27 cat.
(iv) Interfacial tension: Interfacial tension at 27°C should be 0.04 N/m.
(v) Pour point: It should have high pour point at 9°C.
(vi) Flash point: It should have high flash point at 140°C.
(vii) Neutralization value (total acidity): Total acidity of insulating oil should be s minimum as
possible and the minimum value in 0.03 mg KOH/g.
(viii) Corrosive sulphur in terms of classification of copper strip: Insulating oil should be non-
corrosive.
(ix) Dielectric strength or breakdown voltage: It should have high dielectric strength
(x) Dielectric dissipation factors: Dielectric dissipation factor of the insulating oil at 90°C should
be multiple of tan δ (loss tangent) and maximum should be 0.005.
(xi) Specific resistance: The minimum specific resistance of insulating oil at temperature of 25°C
should be 500 x 1012 Ω cm and at temperature 90°C it should be 30 x 1012 Ω cm.
(xii) Oxidation stability: The oxidation stability of insulating oil is as follows:
(a) Maximum neutralization value after oxidation for 164 hours 100°C-0.40mg KOH/g.
(b) Maximum sludge value after oxidation for 164 hours should not exceed 0.1%.
(xiii) Presence of oxidation inhibitor: Antioxidation additives should not be present in insulating
oil.
(xiv) Water content: The amount of water present in insulating oil should not exceed 50 ppm
(part per million).
Understand the procedure of following tests on oil as per I.S.1692-1978:
According to IS: 1692-1978, the following tests may be carried out on the insulating oil to check
its suitability for use.
(i) Dielectric strength test
(ii) Crackle test
(iii) Acidity test
(iv) Sludge test
(v) Flash point test
(vi) Method of field testing of insulating oil
(vii) Sight test
(i) Dielectric Strength Test
Dielectric strength of transformer oil is also known as breakdown voltage of transform oil or RDV
of transformer oil. Breakdown voltages is measured by observing at what voltage sparking strants
between two electrodes immerged in the oil, separated by specific pap Low value of BDV
indicates the presence of moisture content and conducting substances in the oil. For measuring
breakdown voltage of transformer oil, portable.
The dielectric strength of insulating oil is carried out with testing sot which consists of a standard
oil test cell which is approximately 55 mm x 90 mm x 100 mm. In this cell are fitted polished brass
spheres 12.7 or 13 mm in diameter horizontally The gap spacing between these sphere's is 2.5
0.02 mm, which can be adjusted by arrangement to change with the help of attachment with
spheres and can be checked.
Electrical circuit for dielectric strength test

(ii) Crackle Test
This test is performed to check the presence of moisture in the insulating oil. To perform this
test, a sample oil of 250 ml in taken in a breaker. One iron rod of 12.5 mm is made red hot and
dipped in this sample of oil. If there is any hissing sound coming through the oil in the breaker, it
indicates the presence of moisture contents in the oil which will be considered not suitable for
the use.
Crackle Test
(iii) Acidity Test
According to IS: 1866-1983 it is defined as the measure of free organic and inorganic present
together in the oil. It is expressed in terms of the number of milli-grams of potassium hydroxide
required to neutralize the total free acid in one gram of material. Tendency of the oil to develop
acidity requires to be carefully watched. If the acidity exceeds prescribed limit metal surface
above oil level are likely to the corroded on account of acidic vapours. Total acidity can be
calculated by following formula.
56.1×NV
Total acidity=
w
where
N= Normality of KOH solution
V=Volume of KOH solution in millilitre
W=Weight of the sample of the oil in gram.
Hence, the lower limit of acid in the oil is recommended as follows:
(i) Acidity up to 0.45 mg KOH/g Insulating oil is right.
(ii) Acidity in between 0.45 mg to 1 mg KOH/g - Insulating oil should be checked periodically.
(iii) Acidity exceeds 1.0 mg KOH/g - Clean oil or replace it.
(iv) Sludge Test
Used insulating oil may contain some solid materials like rust, scale, dirt, fibre etc.
Method for testing sediment and precipitable sludge is discussed below.
Take the sample of the insulating oil and stir it well until the sediments and precipitated sludge
get mix up with the oil. Now take 10 gram of oil in triangular flask. And add 100 millilitre n-
heptane in the solution. Then stir well the solution of oil and n-heptane and put this solution in
dark for 18 to 24 hours.
If now any solid material is found in the flask, then filtered the solution by tared glass sintered
glass crucible. Now wash crucible and sediment with n-heptane untill the solution become free
from sediment. Now put this crucible in electrical hearth for one hour at the temperature of 100
to 110°C. Then put this solution in desicator for cooling and note down the weight of the solution.
After doing all this again note down the ratio percentage of the crucible solution to the original
solution. And name this value an 'A'.
Mix toluene, acytone and alcohol in this crucible solution in equal quantity and put it for the
further treatment at the temperature of 50°C until sludge completely dissolve in it.
Then filter this solution and separate sludge from the crucible solution. And then inspect visually
whether the solution contain any residue or not.
If any more sediment and sludge is found in the solution. Then follow the same processer again
and again. Calculate the ratio percentage of the weight of residue to the weight of the oil. And
name is as 'B',
Difference between A and B i.e., A-B shows the value of sludge in the oil.
(v) Flash Point Test
Flash point test can also be called as breakdown test. This test is performed to check the dielectric
strength of the transformer oil. The point at which the spark occurs and transformer trips is
known as flash point.
The sample of oil is drawn from near the top and bottom of the transformer and tested in the oil
testing set. A lower than 30 kV dielectric strength for a 4 mm gap of electrodes would indicates
presence of moisture in the oil. The actual testing is done as follows.
The gap of the electrodes is first checked with a gauge. The cup is then filled with sample oil to
be tested upon about one cm, above the electrodes. The cup top is covered with a clean glass
plate. The supply is switched on and voltage is raised gradually by the variac, the stage comes
when the final breakdown of the oil takes place and the circuit breaker is got tripped which
disconnects the transformer from the main supply.
This value is noted down which must be 30 kV (rms) for 4 mm ± 0.02 gap and 20 kV (rms) for 2.5
mm gap. The test is performed with two or three consecutive samples of oil turn by turn with
interval of one minute to allow the bubbles to escape. Average of all subsequent tests is
considered as the breakdown voltage of oil sample.
Testing equipment for flash point test

(vi) Method of Field Testing of Insulating Oil
According to IS. 1692-1978, method of field testing follows: Filled distill water in clean beaker.
Now pour a drop of oil in the beaker through pipette. It is noticed that the drop of the oil start
floating on the surface of the water. Measure the diameter of the drop. If it is found that the
diameter of the drop is in between 15 to 18 millilitre, then oil is right and can be used further. It
the diameter of the drop, exceeds 18 milli-litre, then filter the oil and use it. If the diameter
exceeds 26 millilitre, then the oil cannot be used anymore.
Drop test of insulating oil

(vii) Sight Test
As per IS. 1692-1978 this test can be performed by taking water in the beaker and bent tube is
filled with sample oil. The level in the tube of the oil should not be less than 35 mm by level of
water in the beaker.
Sight Test
Close the end of the tube and fix it on the stand by dipping into water. If the bubbles appear at
the jet, then it will indicate the presence of moisture contents in the oil. This test is rarely used
because the oil testing set is not easily available in the laboratories.
Vacuum impregnation:
Vacuum Pressure Impregnation (V.P.I) is a process by which a fully wound electric apparatus
stator or rotor is completely submerged in a Resin. Through a combination of dry and wet
vacuum and pressure cycles, the resin is assimilated throughout the insulation system. Once
thermally processed, the impregnated windings become a monolithic and homogenous
structure.
The resulting benefits are;
i. Higher Dielectric Strength,

ii. Increased Mechanical Strength,
iii. Greater Thermal Inductivity,
iv. Superior Protection against the Ingress of Water, Chemical and Containments
The VPI process is a significant technological advancement over the traditional “dip in varnish
and then bake” approach used to insulate electric motors. In place of standard insulating varnish
for electric motors, a special VPI epoxy insulation is used on the coils. The preheated stator or
rotor is then lowered into the VPI pressure chamber and a vacuum is drawn. As that occurs, a
solventless epoxy resin is drawn into the chamber until the unit is completely submerged.
Pressure is then applied and the unit becomes thoroughly impregnated with the resin, and then
the unit is removed and baked in a curing oven. The result of the VIP process is a 4 to 5 ml build
of insulating resin and an almost void-free insulation system for your motor’s windings.
Vacuum impregnation is carried out in a vacuum impregnation plant which consists of a double
jacketed vacuum impregnating chamber which has a removable top cover. The chamber can be
heated by circulating steam or hot oil through jacket. There is a chamber for storing the baking
type of varnish. A compressor cum vacuum exhauster which can create a desired pressure or
vacuum by using proper valves is connected to the chamber.
Vacuum impregnating plant

First the wound armature, stator or rotor is placed in the chamber by opening the top cover.
Then it is tightly closed. The chamber is then heated up to 100°C by circulating steam or hot oil
through the jacket of chamber and the temperature is maintained for nearly four hours. During
this period the air from the chamber is pumped out by vacuum exhauster and vacuum is
maintained, which will help in vapourising the moisture present in the coils and removing the
same completely.
Then the insulating varnish form varnish tank is allowed to flow into the chamber till the varnish
in the chamber comes upto a level in which windings are completely immersed. Then the valve
of varnish tank is closed and a pressure from compressor of about 1.4 to 2.1 kg/cm2 is applied
above varnish surface, which will make the varnish to be forced in all the porous (air packets etc)
spaces in the interior of coils. The pressure is maintained for an hour or half an hour and the valve
of the varnish tank is opened and varnish is made to flow back to the tank under air pressure till
excess varnish also gets drainned out. The valve is then closed and the armature is then baked in
the chamber at 100 to 110°C for nearly 8 hours or till the varnish is completely dried out or fill it
becomes bone dry. The air pressure and circulating steam or oil in the jacket is then stopped and
the armature or stator is then removed by opening the top cover.

Testing & maintenance of insulation

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Testing & maintenance of insulation

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Unit-4: Testing & maintenance of Insulation Ghatal Govt.

Testing & maintenance of Insulation

Classification of insulating materials as per I.S. 8504(part III) 1994:

glass fabric, flexible

EFFECT OF TEMPERATURE AND MOISTURE ON INSULATION RESISTANCE

Effect of temperature Insulating resistance

FACTORS AFFECTING THE LIFE OF INSULATION

1. Processing materials Poor quality elements, damage to elements in preparation,

Methods of measuring temperature of internal parts of windings/ machines

(ii) Determination of Temperature-Rise by the Embedded Temperature Detector (ETD) Method

80°C for Class E insulation of windings

Electrical circuit for dielectric strength test

Testing equipment for flash point test

Drop test of insulating oil

i. Higher Dielectric Strength,

Vacuum impregnating plant

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