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AB B MOT ORS A ND GE NER ATORS SER VI CE

ABB Ability™ LEAP

Life Expectancy Analysis Report of Stator Winding Insulation

ABB contact: Mrs. Eva Stenberg Customer: Customer 123

Phone: +46 21 34XXXX Site name: Site 456

Email: eva.stenberg@se.abb.com Serial No: 493XXXX

Report number: 218031 Machine ID: Unit 2

Report date: 09-12-2018 Reference: Mr. Adam Smith

Status/Revision: - Phone: +46 21-1234 5678

Email: adam.smith@customer.com

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TABLE OF CONTENTS

Machine Details…………………………………………………………………………………….….2

Other Information ................................................................................................................ 3

Overall Summary .................................................................................................................. 4

Life Cycle in general ................................................................................................................... 5
Actual Life phase ........................................................................................................................ 6

Recommendations ................................................................................................................ 7

Life expectancy analysis report ........................................................................................... 8

Life Chart .............................................................................................................................. 8

Measurements & Analysis .................................................................................................. 10

Polarization-Depolarization current analysis (PDCA) ......................................................... 10
Tan delta & Capacitance analysis (TDCA) .............................................................................. 11
Non-linear insulation behavior analysis (NLIBA) ................................................................. 14
Partial discharge analysis (PDA) ............................................................................................ 15

Appendix ............................................................................................................................. 17
Observations & Comments ...................................................................................................... 17

LEAP Additional Information ............................................................................................. 21

Insulating materials for high voltage stator coils ................................................................21
Polarization & De-polarization current analysis (PDCA) ..................................................... 22
Tan delta & Capacitance analysis (TDCA) ............................................................................. 24
Non-linear insulation behavior analysis (NLIBA) ................................................................. 26
Partial discharge analysis (PDA) ............................................................................................ 27
Life expectancy analysis ......................................................................................................... 28

Issued by : RM – Motors & Generators LEAP Centre of Excellence

Tested by:

Date for testing:

Prepared by:

Reviewed by:

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Machine Details
Name Plate Information

Customer Stanwell

Machine Identification/Tag ID Unit 2

Serial No 4935699

Make/Manufacturer ASEA

Model/Type Air Cooled Vertical Generator

Power Rating (kW) 35100

Voltage (kV) 11

Current (A) 2047

Frequency (Hz) 50

Speed (rpm) 600

No. of Poles 10

Power Factor 0.9

Insulation Class F

Manufacturing Year 2011

Commissioning Year 2011

Application Generator

VFD Driven 2047

Additional information -

Other Information
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) 29°C

Ambient Temperature (during testing) 22°C

Maintenance History

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Overall Summary

Healthy Low likelihood of presence of severity of defects and abnormalities. Follow

normal maintenance program.

Tolerable Considered acceptable for long-term continuous operation. Follow normal

maintenance program and review recommendations as specified under
recommendations.

Weak Not acceptable for long-term continous operation. Plan for overhaul and
defect mitigating actions within the recommended maximum specified time.

Critical Require immediate action and machine to be put into service only after the
recommended maintenance.

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Life Cycle in general

The motor or generator will be in the following three phases during its life time.
1. Follow ageing and stress – Focus in this phase is to reduce the stress to secure that the
machine is following the predicted design curve.
2. Before overhaul / upgrade – Focus in this phase is to confirm stator quality before decision of
maintenance or major investment.
3. Close to end of life – Focus in this phase is to mitigate risk of failure and prioritize repair /
replacements / upgrades.

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Actual Life phase

Actual life phase:

Comments:

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Recommendations
Nature of maintenance
When?

Further Maintenance

Stress Risk Why Defect Mitigation Action

contributors/Defects Level

End Corona
Protection

Presence of
Contamination/
Nature of
contaminant

Internal Discharging

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Life expectancy analysis report
Operational hours (As per given data) 44586
Starts/Stops (As per given data) 2505

Equivalent hours
(Op. Hours+ Starts/stops*8)

Maximum winding temperature (°C) 80°C

Life used (%)

Remaining Useful Life

Life Chart

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The life expectancy analysis is done with a confidence level of 80% and considers some points as
under:

a) The 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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Measurements & Analysis
Polarization-Depolarization current analysis
(PDCA)

U V W UVW Normal range

IR (Insulation Resistance) [MΩ] 1913 1990 1909 728 ---------

PI (Polarization Index) 3.44 3.45 3.44 3.54 >2

T1 (Ion Migration Time Constant) [secs] 17.64 17.95 16.38 18.88 10-30 Sec

T2 (Slow Relaxation Time Constant) 113.96 111.95 118.16 107.12 65-150 Sec

T3 (Interfacial Polarization Time 783.14 765.15 815.21 791.76 300-1000 Sec

Q1 (Charge - Ion Migration) [%] 10.39 9.49 10.15 13.33 <7%

Q2 (Charge - Slow Relaxation) [%] 16.08 14.97 17.17 14.68 < 10 %

Q3 (Charge - Interfacial Polarization) [%] 35.43 33.55 34.91 39.27 < 20 %

Q1/Q2 64.63 63.39 59.09 90.78 55-65 %

Q2/Q3 45.38 44.63 49.2 37.39 55-65 %

AgF (Ageing Factor) 54.73 58.28 51.42 51.71 35-100

Ic/Ir -17.69 17.85 -6.71 2.68 ----------

Co/C∞ (Dispersion Ratio) 1.62 1.58 1.62 1.67 < 1.25

I∞ (Charging Current At Long Times) 0.47 0.46 0.48 1.11 ----------

ρv (Volume Resistivity) [Log Scale] 13.84 13.85 13.83 13.94 > 14

CI (Ion Concentration Index) 0.02 0.03 0.02 0.03 0.015-0.025

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Tan delta & Capacitance analysis (TDCA)

Voltage U Phase Voltage V Phase

(kV) (kV)
TD (%) CAP (Pf) TD (%) CAP (Pf)

1.08 0.47 201200 1.05 0.44 199800

1.59 0.48 201400 1.56 0.44 200100

2.04 0.48 201400 2.07 0.46 200100

2.56 0.50 201500 2.64 0.48 200200

3.08 0.51 201500 3.14 0.48 200200

3.56 0.52 201500 3.63 0.51 200200

4.05 0.54 201400 4.11 0.52 200100

5.05 0.57 201500 5.08 0.55 200200

6.04 0.60 201500 6.15 0.59 200300

6.32 0.62 201500 6.42 0.60 200300

Voltage W Phase Voltage UVW Phase

(kV) (kV)
TD (%) CAP (Pf) TD (%) CAP (Pf)

1.06 0.41 200000 1.11 0.44 592600

1.57 0.44 200200 1.63 0.45 592800

2.1 0.46 200300 2.15 0.46 593100

2.59 0.48 200300 2.64 0.48 592800

3.11 0.49 200300 3.12 0.50 592800

3.61 0.50 200300 - - -

4.11 0.52 200300 - - -

5.2 0.56 200400 - - -

6.16 0.59 200400 - - -

6.47 0.61 200400 - - -

1.06 0.41 200000 1.11 0.44 592600

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Calculated parameters

U Phase V Phase W Phase UVW Normal

Phase Range

Effective Phase Shift (deg) 0.29 0.27 0.27 64.85 -

Base Tan Delta TDo (%) 0.45 0.40 0.37 0.41 -

Base Capacitance Co (pF) 23024 24582 23691 59264 -

Discharge Inception Voltage (kV) 0 0 0 3.12 -

Discharging Void Volume Content (%) 0 0 0 0 <0.5

Effective Phase of Discharge (deg) 0 0 0 0 -

Tan delta & Capacitance measurements

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Non-linear insulation behavior analysis (NLIBA)

ODD HARMONICS (Low Voltage) ODD HARMONICS (High Voltage)

10
10

ODD HARMONIC MAGNITUDES (arbitrary units)

ODD HARMONIC MAGNITUDE (arbitrary units)

8
8

7
7

6 U
6 U
V
V 5
5
W
W
4
4 UVW
UVW
3
3

2
2

1
1

0
0 1 3 5 7 9 11 13 15
1 3 5 7 9 11 13 15

EVEN HARMONICS (Low Voltage) EVEN HARMONICS (High Voltage)

8 8
EVEN HARMONIC MAGNITUDE (arbitrary units)

EVEN HARMONIC MAGNITUDE (arbitrary units)

7 7

6 6

5 5
U U

V V
4 4
W W

3 UVW 3 UVW

2 2

1 1

0 0
2 4 6 8 10 12 14 2 4 6 8 10 12 14

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Partial discharge analysis (PDA)

Phase U @ 6.32 kV Phase V @ 6.42 kV

Phase W @ 6.47 kV Phase UVW @ 3.11 kV

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Voltage U Phase Voltage V Phase

(kV) (kV)
Qm (nC) Qapp (nC) Qm Qm (nC) Qapp (nC)

1.07 27.3 27.3 1.05 2730 2730

1.59 20 21.8 1.57 2360 2360

2.04 25.5 25.5 2.07 2180 2360

2.55 25.5 25.5 2.63 43.7 47.3

3.08 23.6 23.6 3.14 40 50.9

3.55 23.6 23.6 3.64 54.6 54.6

4.06 23.6 25.5 4.09 40 50.9

5.04 23.6 23.6 5.09 54.6 54.6

6.05 23.6 27.3 6.13 50.9 50.9

6.34 29.1 29.1 6.42 25.5 25.5

Voltage W Phase Voltage UVW Phase

(kV) (kV)
Qm (nC) Qapp (nC) Qm Qm (nC) Qapp (nC)

1070 23.6 23.6 1.11 27.3 27.3

1570 20 20 1.63 23.6 23.6

2.09 23.6 23.6 2.14 30.9 30.9

2.61 21.8 25.5 2.64 23.6 23.6

3.11 21.8 23.6 3.11 30.9 30.9

3.61 20 23.6

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Appendix
Observations & Comments
Contamination

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 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 on the end-windings.
• From the charge distribution ratio Q2/Q3 it is evident that the charge storage on end windings is
greater than that in slot and slot end areas which could be due to presence of contaminants on the
end windings.
• 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.
• Negative Ic/Ir values or Nature of charging curve (PDCA graphs) is indicative of the flow of currents
being controlled by electrochemical charge storage effects, or by presence of homopolar charges.
Homopolar charges can be created by the presence of moisture in the contaminant or due to
excessive humidity, or even due to the presence of metal oxides residues such as iron oxide from
magnetic slot wedge wear or slot discharging effects or even from rust deposits due to moisture.
• The volume resistivity values for individual phases are below the normally observed values and is
mainly suspected due to leakage current flowing between end windings or in termination area.

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. Inadequate electrical contact
could be attributed to the presence of impregnating resin in localized areas between the corona
protection shield and the slot, and not due to damage of the corona protection shield.

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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.
• The partial discharge patterns provided indicate discharing on end windings close to tie-ups and
end winding evolutes.

Ageing of resin

There is no evidence of the presence of mobile ions in insulation due to de-polymerization of the resin
as can be seen from the following:

• The harmonic patterns obtained on analysing the instantaneous admittance of the insulation is
representative of the predominance of end winding located non linear effects, and does not reflect
the presence of an abnormal accumulation of mobile charge carriers within the insulation.
• Patterns obtained from the NLIBA are indicative of a concentration of mobile ions in the insulation
system, particularly in the end-winding insulation.
• 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 “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 no evidence of significant discharging in de-lamination 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

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• There is no evidence of any sustainable discharge activity that was recorded upto the maximum
test voltage, and therefore the extent of de-lamination is insignificant.

Health Index Chart

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LEAP Equipments list [optional]

Instrument Serial Number Model Last Calibration Calibration Due

Date

Insulation
Resistance tester

Multimeter

Humidity meter

Deltamaxx

Doble Transfomer

PD Tech Calibrator

Shunt

Winding resistance
meter

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—
LEAP Additional Information
Insulating materials for high voltage stator coils

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Polarization & De-polarization current analysis

(PDCA)
A D.C. step voltage of known voltage is applied to the windings using a highly regulated electronic power
supply. The voltage is maintained for a time period of not less than 1000 seconds and the current flowing
through the insulation is monitored during the charging period. After all relevant data is obtained, the
windings are discharged through a micro ammeter and discharge currents are monitored after the initial
winding capacitance discharge (< 5 secs), over a total time period that will not be less than the charging
time period.

The charging and discharging currents are then plotted on a log-log scale and analysed in the time and the
frequency domains.

The following parameters are computed from the measurements performed:

Ø Insulation resistance & Polarization index

Ø Ion Migration – Charge (Q1)
Ø Slow Relaxation – Charge (Q2)
Ø Interfacial Polarization – Charge (Q3)
Ø Ageing Factor / Mobility Index of the Binding Resin (Agf)
Ø Ion concentration index (CI)
Ø Dispersion Ratio (DR)
Ø Volume Resistivity of the Insulation (VR)

On the basis of the above an assessment of the winding insulation is made with regard to

Ø General insulation quality

Ø Sensitivity of the insulation system to moisture absorption
Ø Presence of contamination in the windings
Ø Condition of the binding resin
Ø Extent of electrical contact of the coil with the slot

Charge storage: The charge storage takes place due various mechanisms such as,

Ø space charge polarization in the slot region (Q1- Ion migration charge),
Ø interfacial polarization at the interfaces of the slot region (Q2 – Slow relaxation charge)
Ø interfacial polarization in the end-winding regions (Q3 – Interfacial polarization charge or end winding
charge).

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

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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.

Q1
Q3
Q2
2

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.

Ageing 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.

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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

Dispersion ratio (DR): The ratio of the capacitance required to store the charge obtained from the
winding during the discharging proces to the geometrical capacitance of the windings, is referred to
as the Dispersion ratio. Values computed for clean and dry insulation normall 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.

References:
Ø IEEE 43: 2013
Ø “Diagnosis of insulation health of rotating machines” by Cajetan Pinto, Maciej Wnek,
CWIEME Proceedings, 2000.
Ø "An Improved Method of detecting contamination of HV stator windings in the field" by
Pinto C 18th E/EIC conference proceedings - Chicago 1989

Tan delta & Capacitance analysis (TDCA)

Tan delta and capacitance measurements are performed using a transformer ratio arm bridge.
Measurements are made both below and above discharge inception voltage, at voltage levels that will
be determined on the basis of discharge inception with the aim of accessing the maximum required
data for analysis. Measurements will be performed at increments that will not exceed 0.2*V L-L.
Maximum test voltage will be (VL-L /√3) kV., r.m.s.

Results will be analysed to obtain the following parameters:

Ø Discharging void volume ratio (if discharges are present)

Ø Effective phase of occurrence of discharges
Ø Effective phase shift to check if the variations are due to stress grading.

The results will be analysed in order to assess the winding insulation with regard to:

Ø Extent of De-lamination (if any)

Ø Condition of the corona protection shield
Ø Non-linear behaviour of insulation that would result in C and Tan delta variations in the
absence of partial discharges

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Tan delta: Tan delta 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.

Discharging 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 delta above discharge inception.

Effective phase shift: The effective phase shift is computed from the variation of C-tan delta
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.

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.

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

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Non-linear insulation behavior analysis (NLIBA)

Non-linear insulation behaviour analysis is to study the non-linear behaviour and characteristics of
insulation material. The tan delta and capacitance measurements vary with voltage even in absence
of partial discharges and one of the most obvious reasons for such behaviour is the presence of non-
linear field stress grading system at slot ends. Other reasons are space charge/interfacial polarization
due to contamination, electrostatic forces on delaminated insulation, increased ionic mobility due to
ageing, surface partial discharges etc. It is evident that both the voltage supply across insulation and
the current passing through the insulation contain harmonics, which cause increase or decrease in
the measured tan delta and capacitance values. Thus, it becomes necessary to understand this time
varying effect of insulation admittance on the capacitance and tan delta measured.

Non-Linear Analysis provides a detailed understanding of such non-linear behaviour, and thereby
supplements the tan delta analysis. The analysis provides additional insights into the aging of
insulation.

The machine insulation is tested at predetermined voltage levels up to a maximum of (V L-L /√3) r.m.s.
The instantaneous admittance of the insulation is then calculated and the admittance patterns are
analysed for specific harmonic patterns.

The extent of harmonics, predominance of odd or even harmonics at high or low frequency harmonics
is analysed to provide information on:

Ø The integrity of the stress grading system used at the slot ends
Ø The contribution of the slot corona protection system, contamination and ageing.

References:

Ø 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.
Ø 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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Partial discharge analysis (PDA)

Partial discharge pulse patterns will be monitored and recorded using a transformer ratio arm bridge
with appropriate coupling capacitors.

The partial discharge pulse patterns will be analysed with regard to pulse count, pulse magnitude,
polarity dependence and phase to identify the nature of discharges which can then be classified as:

Ø Internal Discharges.
Ø External Discharges (like slot, slot end, gap , surface and end winding discharges)

Qapp (Apparent charge): Apparent charge of a PD pulse is that charge which, if injected within a very
short time between the terminals of the test object in a specified test circuit, would give the same
reading on the measuring instrument as the PD current pulse itself. The apparent charge is usually
expressed in picocoulombs (pC).

Qm (Mean charge): It is the magnitude associated with a PD pulse repetition rate of 10 pulses per second
(pps), which can be directly inferred from a pulse height distribution in PD display.

References:

Ø IEC 60034-27:2006
Ø IEC 60270
Ø IEEE Std. 1434-2000 - Trial Use Guide to the Measurement of Partial Discharges in Rotating
Machinery
Ø F.H. Kreuger, E. Gulski and A. Krivda, “Classification of Partial Discharges”, IEEE Trans. On
Electrical Ins., Vol. 28 No. 6, Dec 93
Ø 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
Ø B. Fruth, L. Niemeyer, "The Importance of Statistical Characteristics of Partial
Discharge Data", IEEE Trans. on Electrical Insulation, Vol.27, No.1, February 1992
Ø B. Fruth, J. Fuhr, "Partial Discharge Pattern Recognition - A Tool for Diagnosis and Monitoring of
Ageing", CIGRE, paper 15/33-12, 1990

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Life expectancy analysis

A combined stress phenomenological model, that is based on one proposed originally by Simoni, 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 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
grey 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 grey 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.

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