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Method for estimating the lifetime of electric motors insulation

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DOI: 10.1109/ATEE.2013.6563466

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THE 8 INTERNATIONAL SYMPOSIUM ON ADVANCED TOPICS IN ELECTRICAL ENGINEERING
May 23-25, 2013
Bucharest, Romania

Method for Estimating the Lifetime of

Electric Motors Insulation
Catalin Rusu-Zagar1, Petru Notingher2, Valentin Navrapescu2, George Mares3, Gilda Rusu-Zagar1, Tanta Setnescu4, Radu
Setnescu5
1
National Institute for Research and Development on Occupational Health and Safety, Romania
2
University Politehnica of Bucharest, Romania
3
Eurotest S.A.,Romania
4
Valahia University of Targoviste, Romania
5
National Institute for R&D in Electrical Engineering (ICPE-CA), Romania
catalinrusuzagar@gmail.com, petrunot@elmat.pub.ro, valentin.navrapescu@upb.ro, george.mares@eurotest.ro,
gildarusuzagar@yahoo.com, setnescutanta@yahoo.com, rsetnescu@yahoo.com

Abstract- In this paper we present the results of a study over
the aging and the estimating lifetime of a new insulation system
for a DC motor. In order to achieve the lifetime experiments,
a group of 7 motorettes (made under IEC 60216-1) have been
subjected to accelerated thermal aging at T = 260 ° C (for 1000
hours), followed by their requests to vibrations (1 hour) and
humidity (48 hours). At every 200 hours were measured the
insulation resistance, the losses factor and the electric capacity
of motorettes, then these were tested in the AC withstand test
voltage (600 V). The activation energy of oxidation of the enamel
used as insulator of the conductors has been determinated by
Differential Scanning Calorimetry (DSC). Considering as a
diagnostic factor the insulation resistance and using the
activation energy value determined by DSC the lifetime line to
constant stress and then, the lifetime values for different
temperatures were determined.
Keywords: Electric machines, insulation, thermal ageing,
activation energy, lifetime
I. INTRODUCTION
The insulations of electrical machines and equipment in
operation are under continuous mechanical, electric, thermal,
chemical, environmental etc. stresses [1], which cause their
ageing.
Thus, due to conductors defects (not rounded edges,
protuberances, etc..), detachment of wire insulations, cavities
insulation and impurities, different values of permittivity
insulation composite components etc. and accidental large
values of the applied voltage, intense electric fields occur in
isolation [2-4]. These facilitates the development of several
phenomena that contribute to the degradation of insulation:
the emergence of electron injection from conducting wire [3],
the showing up and / or the increasing of partial discharges
on the surface and inside insulations [5], the formation of the
charge cloud [2], the occurrence of electrolysis [1], electrical
trees [6] and electrochemical [2-3] etc..
The effect of different mechanical stresses (stretching,
compressions, vibrations and elongations, different thermal
expansion in heterogeneous systems etc.), may be fissures in
the bulk of the insulation material at interfaces between
materials of the insulation system [7]. Consequently, partial
discharges may arise. As a result of thermal stress the
insulation material degrades [8]. The specific form of thermal
degradation depends on the material nature and structure, but
the most important chemical degradation reactions are
oxidation and hydrolysis. Transient or periodic temperature
gradients may also induce mechanical stresses [1].
Environmental stress may also be of importance [9].
Examples of environmental stress are radiation from the sun,
radiation in nuclear power plants, humidity, and the type and
pressure of the surrounding gas (Table I).
The action of the above-mentioned stress factors cause
ageing of insulation systems. Ageing is an irreversible
deleterious change to the service ability of an insulation
system [1]. Ageing caused by only one ageing factor is
denoted single factor ageing. Ageing resulting from several
ageing factors, either simultaneously or sequentially applied,
is called multifactor ageing.
TABLE I.
AGEING FACTORS
Type Examples
Mechanical Crackings, Tensions, Vibrations
Electrical Overvoltage, Tracking, Partial
Discharges, Electrical Trees,
Electrochemical Trees
Thermal Oxidation, Hydrolysis
Environmental Gas, Acids, Pressure, Radiation,
Water
Most commonly, failure means breakdown of the
insulation. In this case, insulation life is determined by
measuring the time to breakdown [1]. Doing this in “real-
time” would have been rather exhausting, given that most
insulation systems are expected to endure ageing for several
decades before failure occurs. Instead, the ageing process is
accelerated in laboratory tests so that insulation life is
severely reduced. This is done usually by increasing the
intended design stress. From the results of accelerated ageing
tests, insulation life at service conditions can be estimated
from appropriate ageing models.
 II. LIFETIME ESTIMATION MODELS In this model, Crine suggests that the ageing process can be
characterized by an energy barrier which separates the initial
Because all the degradation processes lead to the reduction
“good” insulation (state A) from the final breakdown or
of the insulation lifetime, many methods of lifetime
failure state (B) and that the time to cross the energy barrier is
estimation based on the accelerated electrical, thermal and
the lifetime of the insulation D (T , E ) :
mechanical life tests were developed [10-25]. These ageing
mechanisms can be done under the action of a single stress
factor (single factor ageing) or a multifactor stress h ΔG eλE
D(T , E ) = ( ) exp( )csch ( ), (8)
(multifactor ageing) [3], [11-12], [25]. k T k T k T
B B B
A. Single factor ageing models
a) Dakin thermal ageing model [13] where h is the Planck constant, kB is the Boltzmann constant,
ΔG is the free energy of activation, λ is the distance between
D1 = A1exp(B1/T) (1) A and B, csch is the hyperbolic cosecant and e is the charge of
b) Electrical ageing models (inverse power law) the particle taking part in the ageing process.
D2 = A2E-n (2) C. Sinergistic models
If an insulation material is subjected to both elevated
and exponential model temperature and an electrical field, then the result may be that
D3 = A3exp(-B3 E). (3) failure occurs much sooner than if the two stresses were
applied separately. The resulting ageing is not necessarily the
c) Mechanical ageing model algebraic sum of the thermal ageing and the electrical ageing.
D4 = A4exp(-B4 σ), (4) In most cases new failure mechanisms may be created when
several stresses are present. The synergy effects are due to
where D1,2,3,4 represent the lifetime of aged insulations at interactions between different ageing factors. There are two
temperature T or electric field E or mechanical strain unit main types of interaction: direct interaction and indirect
factor σ, and A1,2,3,4, B1,2,3,4 and n are material constants interaction [1], [22].
(dependent on the temperature etc.) [14-15]. Direct interaction is “interaction between simultaneous
B. Multifactor models applied factors of influence, which differs from that occurring
In the case of multifactor ageing, models such as Simoni with sequentially applied factors of influence” [1]. An
[15], [23], Ramu [16], Fallou [17], Cygan – Laghari [18], example of direct interaction is oxidation. Both oxygen and
Crine [19], space charge [14], [20], electrical trees [14], elevated temperature are needed at the same time to give
partial discharges [21] etc. can be remarked. Some of these synergy effect.
models are presented in [1]. Indirect interaction is “interaction between simultaneous
In the Simoni’s model the insulation lifetime D and ageing applied factors of influence, which remains essentially
rate R are inversely proportional quantities and the ageing unchanged when the factors are applied sequentially”[1].
rate R(T,E) describes the thermal-electrical ageing process: Indirect interaction can only be brought about by ageing
B b factors.
R(T , E ) = A exp(− ) exp((a + ) f ( E )) (5) For electrical motors insulation, mechanical and electrical
T T
stress may cause interaction. Voids created by the mechanical
where E is the electrical field, T is the temperature, f(E) is an stress may give rise to partial discharges. If the voids are
unspecified function of the E, and a, b and B are constants. formed only when mechanical stress is present, the ageing
Ramu’s model is obtained from a multiplication of would be caused by direct interaction between mechanical
classical single stress rates: and electrical stress. Indirect interaction, however, occurs if
− n(T ) 1 the voids formed due to the mechanical stress are permanent.
D (T , E ) = c(T ) E exp(− BΔ( )) (6)
T The insulation system may first be exposed to the void
1 1 producing mechanical stress, and subsequently to an electrical
where c(T ) = exp(c1 − c 2 Δ( )) , n(T ) = n1 − n 2 Δ ( ) , stress, or the two ageing factors can be applied
T T simultaneously. The fact that stress factors may interact must
Δ(1/T) = 1/T – 1/T0 and c1,2 and n1,2 are constants. be taken into account in the life models.
Fallou has proposed a semi-empirical ageing model based III. THERMAL LIFETIME ESTIMATION
on the exponential model for electrical ageing:
A. Montsinger’s Model
B( E ) In the Montsinger’s model it is considered that insulation
D (T , E ) = exp( A( E ) + ), (7)
E degradation under thermal stresses action due to chemical
reactions whose characteristic rate varies with temperature
where A(E) = A1 + A2E, and B(E) = B1 + B2E and A1,2 and B1,2 according to Arrhenius law
must be determined experimentally from time-to-breakdown
curves at constant temperatures.
 k (T ) = k 0 exp(− E a / RT ) , (9) insulation temperature [25].But as this test is very long in this
paper we propose to use a faster method, namely activation
where k(T) represents the ageing rate constant, k0 is a
constant, Ea is the activation energy and R is the gas constant,
and the lifetime LM(T) can be estimated with the equation:

L (θ ) = A exp(− B θ) , (10)
M M M

where AM is the insulation lifetime at 0 °C, BM – a material

constant and θ – the temperature (measured in °C) [23].
By applying natural logarithm function to this equation
(10), it is obtained:

lnLM = aM– bM·θ. (11)

where aM = lnAM and bM = BM..
Fig. 1. Accelerated thermal ageing curve
Experimental determination of insulation lifetime involves
the study of electrical, mechanical or chemical properties
variation during thermal ageing. Thus, the variation curves of
the chosen property P (respectively, p = P/ P0, where P0
represents the initial value of property P) are drawn in time,
for each temperature value and the intersections of these
curves with the horizontal line of the chosen end-of-life
criterion peol are determined (Fig. 1). Intersection points
Q1(θ1, τ1), Q2(θ2, τ2) and Q3(θ3, τ 3) are determined using the
graphic method, then they are used to draw the thermal
lifetime curve in semi-logarithmic coordinates x = θ and y =
ln τ (Fig. 2). The advantage of this representation is that
tracing the curve can be done with two measurements and the
extrapolation to regime temperatures is easier. Fig. 2. Lifetime curve drawn using the points Q1(θ1, τ1), Q2(θ2, τ2) and Q3(θ3,
τ 3) from Fig. 1.
B. Dakin Model
The most known and used method for estimation of energy method (AEM), which requires only a thermal aging
insulation lifetime is based on chemical rate theory and it was test (lasting the lowest) and experimental determination of
proposed by Dakin [13]. Considering that the property p activation energy Ea [26].
reaches the value peol, the time needed to reach this value, For this, it is considered that the thermal degradation
respectively the thermal lifetime (DD(T)) has the expression: complies with Dakin equation (16) and the parameters aD =
lnAD and bD = Ea/R of the lifetime line (17) are determined
LD = AD exp( BD / T ) (12) based on experiments corresponding to an accelerated
thermal ageing at the highest temperature [24].
where AD and BD are material constants.
From (16), the equation of thermal lifetime is obtained: A. Experiments
Thermal aging were performed on motoretts made from
ln LD (T ) = a D + bD / T copper conductor with the diameter of1.2 mm, insulated with
(13)
Elmotherm 073-1010 varnish. The insulation between layers
where aD = log AD and bD = -BD = Ea/R are material constants. and from the metallic frame in which the motoretts were
As with Montsinger model, making three accelerated aging
on samples of insulation tried at selected temperatures (T1,2,3 =
θ1,2,3 + 273.15 K) according to IEC 60216-1 [25], one can
determine the straight line of lifetime lnDD = f(1/T) then the
lifetime value at any operating temperature of the insulation.
IV. ACTIVATION ENERGY METHOD
Experimental determination of thermal lifetimes straight
lines described by equations Montsinger (11) and Dakin (13)
involves conducting accelerated aging at three temperatures,
the lowest being as close as possible to the operating
Fig. 3. Motorette before the thermal conditioning.
mounted was made from Nomex (Fig. 3). Before the thermal
ageing, the first set of 7 motoretts was subjected to a thermal
conditioning at 200 oC for 72 h. At the end of the
conditioning, a visual inspection was performed and electric
properties measurements were done (Riz, C, tgδ, power
frequency withstands voltage).
The motoretts were thermally conditioned and aged in a
WS 200 oven with an automated monitoring of the internal
temperature and air flow, a programmable data acquisition
and automated shutdown. The control system was done using
control and acquisition models and the virtual instrumentation
software Lab.View 9.
The thermal ageing was carried out in several cycles, each
cycle containing a thermal ageing sub-cycle and a diagnostic
sub-cycle (mechanical stress, humidity stress, voltage stress).
The durations of the ageing sub-cycles were of 2 days. After
each sub-cycle, the insulation resistance, capacity and loss
factor were measured and a 600 V voltage was applied
between the coils and ground, for 10 min.
The mechanical stress from the diagnostic sub-cycle was
done by subjecting the motoretts to mechanical stresses on a
vibration table for 1h, at ambient temperature. The vibrations
amplitude corresponds to a 1.5 g acceleration (peak-peak
amplitude was 0.3 mm at the frequency of 50 Hz).
The vibration stresses were done using an adjustable
vibrator, model Ve 1000, having an electrodynamics drive
and frequency range between 5 and 3000 Hz. The equipment
command and control, data acquisition and processing were
done using a PC with a LabVIEW software, with (DAQ)
interfaces from National Instruments.
The humidity stress was done in a condensation room for
48 h, at temperatures between 15-35 ⁰ C. During these tests,
condensation drops were noticed on the coils, without being a
water flow. The temperature and air humidity inside the room
were monitored. The humidity stress was done in an ILKA
climatic chamber (humidity 85%, at a temperature of 30 °C).
The power frequency withstand voltage stress (600 V) was
done for each sample, to determine the life ending moment.
Differential Scanning Calorimetry measurements were
performed in non-isothermal mode (temperature ramp) at
different heating rates, namely 2, 4, 6 and 10°C/min in
presence of air (gas flow, 50 ml/min). The instrument was a
Setaran DSC 131 EVO (Setaram Instrumentation, France).
The sample mass was 18.5 ± 3 mg and the aluminum
crucibles (100 μl) were sealed with aluminum caps enabling
an oxidation chamber of around 60 μl. A typical curve
recorded in non-isothermal mode showing the oxidation peak
and the kinetic parameters characterizing the oxidation
process is shown in Fig. 4.
The oxidation onset temperature (OOT) was calculated,
according to ASTM E2009-02 [27] as the intersection point
of the recorded baseline and the slope of the oxidation
exothermal, as it is shown in Fig. 4. The thermal effect of
oxidation (ΔHox) as well as the maximum temperature of
oxidation peak (Tm) was calculated as presented in Fig. 4.
Tangential sigmoid mode has been chosen to draw the
baseline of the integral.
Thermal aging was performed on a group of 7 motoretts in
TABLE II.
VALUES OF THE ELECTRICAL PARAMETERS Riz, C AND tgδ
Property Before Afer After ageing
conditioning conditioning (τ = 30 days)
Riz (MΩ) 2.24x106 11.57 x106 1.20
C (pF) 178.92 160.91 436.1064
tgδ 0.0180 0.014136 0.83562
Fig. 4. Example of a DSC curve (heating rate 4 °C /min.) and determination
of the kinetic parameters of oxidation.
TABLE III.
VALUES OF THE OXIDATION ONSET TEMPERATURE (OOT)
Heating rate (4°C/min) OOT (°C)
2 181.25
4 193.24
6 198.49
10 204.85
15 subcycles of 2 days followed, each one by subsequent
wash cycle requests vibration (1 hour) and humidity (48
hours). Before and after conditioning and after each subcycle
insulation, resistance (Riz), capacity (C) and losses factor (tgδ)
were measured (Table II). Then the group of samples was
tested in the AC withstand test voltage (600 V).
Considering as diagnostic factor the insulation resistance
measured after application to moisture and end-of-life
criterion value of 20 MGΩ (that dropped 106 times) it was
determined that the aging time for this value is reached,
respectively DD = 28.5 days = 720 hours. It were obtained the
coordinates of the first point Q1 of the line of lifetime,
respectively T1 = 533.15 K and τ1 = 720 h.
As it was supposed that the degradation of the insulation
system is due to the oxidation of the varnish used as insulator,
the activation energy of the varnish oxidation was used for
lifetime evaluation of the insulation system. The activation
energy of varnish oxidation was calculated using the
oxidation onset values (OOT) as determined from the DSC
measurements (Table III). Different calculation methods of
activation energy were used as is presented below (Table IV).
The values of the OOT, or heating rate (β) were plotted vs the
reciprocal of temperature as indicate the equations of the
isoconversional methods in Table IV. Tf is the temperature at
a fixed transformed amount, i.e. in our case OOT (which
corresponds to the beginning of oxidation) and C1, C2, ,C3, and
C4 are constants.
As well, the activation energy of the oxidation process was
evaluated following the ASTM E698 [32], a method based on
plotting lnβ vs. 1/Tm.
 In all mentioned cases, the plots of the above equations are
straight lines, with slopes equal or proportional (in the case of
Ozawa's method) to -Ea/R (Fig. 5). The mean value of the
activation energy Ea,a = 115.5 kJ/mol (used in subsequent
lifetime estimations) was calculated as the arithmetic average
of the Ea values (Table V).
TABLE IV
ISOCONVERSIONAL METHODS RECOMMENDED FOR
ACTIVATION ENERGY EVALUATION
Equation (no.) Ea calculation Reference
Plotting
β Ea T2 is
ln =− + C1 (1) ln f
= f (1 / Tf )
T f2 RT f β [28, 29]
obtained a straight line with
the slope -Ea/R
Ea Plotting ln β = f ( 1 / T ) Fig. 5. Kissinger method for Ea determination
ln β = − 1,0518 ⋅ + C2 ( f
RT f is obtained a straight line [29, 30]
TABLE VI.
with the slope -Ea/R 1.0518 INSULATION LIFETIME VALUES FOR DIFFERENT SERVICE
Plotting TEMPERATURES θ, CALCULATED WITH DAKIN (DD) AND
β Ea β is MONTSINGER (DM) MODELS.
ln =− + C3 (3) ln = f (1 / Tf )
Tf RT f Tf [29, 31]
θ (°C) 260 240 220 200 180 160 140
obtained a straight line with
the slope -Ea/R LD (h) 720 1989 5965 19630 71765 295737 1397779
Plotting
β Ea β is LM (h) 720 2072. 5964 17166 49407 142202 409278
ln =− + C 4 ( 4) ln 1.8 = f ( 1 / T f )
T f1.8 RT f Tf [29]
LD (y) 0.082 0.227 0.681 2.241 8.192 33.760 159.564
obtained a straight line with
the slope - Ea/R LM (y) 0.082 0.237 0.681 1.960 5.640 16.233 46.721

TABLE V
ACTIVATION ENERGY Ea VALUES (Tf = OOT) Using temperatures θ1 = 260 oC and θ2 = 220 oC, for whom
Parameters of the correlation lines lnβ/Tf = A + the obtained values were LD1 = 720 h and LD2 = 5694.6 h
Method Equation
B⋅1/Tf
(Table VI), it results: bM = 0.05286 oC-1, AM = 6.696·108 h and
Ea aM = 20.3222. With the aD, bD, aM and bM values, lifetime LD
A B R
(kJ/mol)
and LM values were determined for different service
β Ea
Kissinger
ln
T f2
=−
RT f
+ C1
15.08 -13714.5 0.99375 114.0
temperatures of the insulations (Table VI).
Considering that the nominal temperature of the insulation
Ea
is 180 oC, the thermal lifetime estimated with Dakin and
ln β = −1,0518 ⋅ +
RT f Montsinger models are: LD = 71765.1 h and LM = 49407.1 h.
Ozawa 32.87 -14645.5 -0.99759 115.7
+ C2 For temperatures above 200 °C, the differences between the
values calculated with Dakin and Montsinger models are
β Ea
relatively small (less than 12.5%), but as they grow for lower
Bosw =− + C3
ell
ln
Tf RT f
25.72 -14175.3 -0.99416 117.8 operating temperatures. On the other hand, the activation
energy used in calculating the lifetime was determined only
Starin β Ea for the main component insulation system (respectively, the
ln =− + C4 20.02 -13807.6 -0-99382 114.7
k T f1.8 RT f varnish). Obviously, its value changes when taking into
account the entire insulation system.
Occur during motor operation, permanent, and mechanical
The value of constant aD is calculated from the lifetime line stresses (vibrations etc.) and those of the environment
equation, respectively aD = lnDD - bD/T1 = ln720 – (humidity, radiation and so on). In the experiments submitted
13897/533.15 = -19.4917. It results AD = 3.441·10-9 h. in this work the duration of these requests were relatively
For the calculation of the constant bD (from lifetime line low. Moreover, because of varying loads of engines loading,
equation), the mean value of the activation energy Ea,a was the temperature does not remain constant, appearing
used, respectively bD = Ea/R = 13897 K. sometimes significant variations. Therefore, a more correct
To determine the constants aM and bM (from the Montsinger activation energy will have to consider these requests and
Model (13)), a condition must be imposed, that for two their synergistic effect.
ageing temperatures θ1 and θ2 (respectively, T1 = θ1 + 273.15 The using of the activation energy for plotting the line of
and T2 = θ2 + 273.15, in K), lifetime values obtained using lifetime is a quick method to characterize new insulation
Montsinger (LM1(θ1) and LM2(θ2)) and Dakin (LD1 and LD2) systems (or those in which it has been replaced a component).
models must be identical (LM1 = LD1 and LM2 = LD2).
Using the aging temperature θ1 = 260 ° C, the duration of
thermal aging test (15 cycles of 2 days) was of 30 days.
But its validation requires performing three aging and
drawing this line through three points. However, considering
two other aging tests at θ1 = 240 ° C (15 cycles every 14 days
and θ1 = 220 ° C (15 cycles every 28 days) (see [26]), during
testing reached 660 days, respectively is 22 times higher.
V. CONCLUSIONS
This paper presents a short analysis of models and methods
for estimating the useful life of electrical insulation electrical
motors and proposes a fast method to estimate their useful
lives using the activation energy. Using the activation energy
can reduce the test duration over 20 times.
Lifetime line use as drawn with Montsinger method leads
to significant errors in the estimation of the lifetime of
insulation to lower operating temperatures, respectively
Montsinger model is less appropriate than the model Dakin.
Lifetime estimation method based on the activation energy
determined by DSC will to checked by making two more
accelerated aging of varnish at two different temperatures
close to the nominal motor operating temperature
(respectively, at 240 and 220 oC) .
For determining the line of duration it has been considered
that the heat stress is constant, corresponding to a constant
load motors. An account of the life and lifetime reserve
engine which are running at variable load will be presented in
a future paper.
ACKNOWLEDGMENT
A part of this work has been supported by the Romanian
Ministry of Research and Higher Education and European
Commission, FP7 Programme, SP1-JTI-CLEAN SKY-2009-
2, ELETAD Project.
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