2-Stator Winding

This material shall not be copied or published without the written approval by Siswanto
A. High Voltage Insulation Winding Systems and

Constructions
Insulation winding on the rotating electrical machines including
generator are classified by thermal class. Following table is
thermal class on for the winding insulations,
1.Class A: Permissible Max temp winding = 1050 C
2.Class E: Permissible Max temp winding = 1200 C
3.Class B: Permissible Max temp winding = 1300C
4.Class C: Permissible Max temp winding ≥ 2000 C
5.Class F: Permissible Maxi temp winding = 1550 C
6.Class H: Permissible Maxi temp winding = 1800 C
A.2. Winding Constructions
The insulated copper conductor bars that are use for winding are
distributed around the inside diameter of the stator core,
commonly called the stator bore, in equally spaced slots in the
core to ensure symmetrical flux linkage with the field produced by
the rotor. Each slot contains two conductor bars, one on top of the
other (see figure 2-1.Stator winding construction in the slot).
These are generally referred to as top and bottom bars. Top bars
are the ones nearest the slot opening (just under the wedge) and
the bottom bars are the ones at the slot bottom. The core area
between slots is generally called a core tooth.
Wedge
Packing
Stator Core
Stator Core Separator

(Cooling Duct)
Stator Dovetail Tooth
Side Ripple Top Filler

Packing
Radial Spring
Semiconductive Bar
Armor
Groundwall
Insulation
Slot Separator
Transposition Filler
Fig. Stator winding
Solid Copper Strand construction in the
slot.
A.2.1. Coil Material Properties in History
Stator Winding basically are designed based on to thermal class and
voltage rating of the machine. Higher voltage rating need much layer on
the winding insulations, insulation construction see above.
For old machines (build within year 1930s) the manufacture began
utilizing asphalt as the bonding agent for the insulation of large
synchronous machines. A asphalt was used to bind mica flakes ( called
asphalt micafolium) to form the wall insulation or was used to bond the
mica flakes to a tape (called asphalt mica tape), for the modern machine
(1950s) the manufacture was gradually replaced by thermo plastic
insulation (called thermosetting insulation).
Asphalt based insulation systems are prone to develop a number of
problems that are very specific to the thermal class of insulation. A major
disadvantage of the asphalt-based insulation is its poor thermal resilience.
When exposed to high temperatures, the asphalt develops a sharp drop in
viscosity and thus tends to migrate along to the coil to areas of less
pressure, its can allowed flow out of the coil.
A.2.2. Coil winding construction step-by step manufacturing
process. :
•Copper strip (wire strand)
The conductivity copper of winding at least minimum 99.9 % and no
surface defect
•Strand / Turn insulation
Turn insulation normally consisting of mica tape (sometimes enamel
depending on space availability) with a special adhesive coating that
melts at high temperature to bond and consolidate the insulated
strands. The consolidation is carried out in the special presses and
therefore ensure a correctly dimensioned wire pack, which does not
move during manufacture and conductor do not oscillate during
operation.
LOOP WINDING
Roebbel Winding
The currents normally flowing in large turbo generators can be in the order of
thousands of amperes. Due to the very high currents, the conductor bars in a turbo
generator have a large cross-sectional area. In addition they are usually one single
turn per bar, as opposed to motors or small generators that have multiple turn
bars or coils.
The high current capacities of copper in the stator bars generate significant
heat. The losses due to the flowing currents are called I 2R losses in the winding
The magnetic field tends to be more intense toward the top of the slot, and
therefore the top bars generally produce more heat than the bottom bars.
Within the bars themselves, there are also “eddy” currents flowing in each bar
caused by the localized leakage magnetic field. To reduce the effect of the eddy
currents within each individual stator bar, the conductors are made up of numerous
copper “strands” . This is similar to the reasoning behind the stator core being made
up of laminations rather than a solid mass of steel
However, although the strands are insulated from one another in the bar, they are
eventually connected at each end of the stator bar.
Therefore additional circulating current could flow from top to bottom
strands in a single bar. This is due to the difference in the magnetic
field from the top to bottom of the slot. To reduce the effect of the
circulating currents, the strands are “Roebel Transposed” in each
bar.
Roebel transposition of the copper strands refers to the re-

positioning of each strand in the stator bar stack such that, it
occupies each position in the stack at least once over the full length
of the stator bar.
There are 360 and 540 degree Roebel transpositions found by and
large. A 360 degree transposition means that each strand
occupies each position once over the length of the bar, and a
540 degree transposition means that each strand occupies each
position one and a half times. The 360 transposition is generally
done in the slot only and the 540 transposition is done out to the
very ends of the stator bars, and in the curved end-winding portion
as well.
Roebbel Winding
Roebbel Winding
Roebbel Winding
ROEBBEL WINDING
a insulation tapping systems
a.1 Wrapping by discontinuous method
The manufacturing of coils using mica tape can be achieved by the
discontinuous method ways: The main insulation is applied to the un-
stretched coil. Both slot section of the coil are wrapped with full
width mica tape and then pressed. The edge of insulation are cleaned ,
Mica –paper tape are then used to insulated the end winding using special
tape (example FEINMICAGLAS or CALMICA-FLEX – ISOVOLTA Product)
flexible end winding tapes. These tapes should join up flush with the end of
main insulation
a.2. Wrapping by continuous method
By using Mica tape ( example by CALMICAGLAS®- Isovalta product) in
tape form the straight slot section and overhang can be taped in a
continuous taped sufficient distance around the first slot section
bend, . The conductor stack is taped half-overlapped is then pressed and
the end winding cured in oven if necessary with a varnish. During tapping
process uniformly tape thickness and tension around in the coil section
must be maintained to achieve desired void free structure of correct
density
Insulation Wrapping
The nominal thickness of CALMICA® is 0.16 mm as supplied and
approximately 0.125 mm when pressed.
The no. of insulation layer materials required can be calculated by referring
to the technical data showing values after pressing.
Table : Table tapping thickness
Example:
Un = 12 kV, the insulation thickness would be 2.8 mm.
Utilize the insulation CALMICA 0.16 mm with approximately 0.125 mm when
pressed,
The no of layer required : 2.8 / 0.125 = 22.4 layer app. 23 layers must be
applied on to coils winding
Un KV ≤4 6 10 12
Thickness mm 1.0 1.5 2.5 2.8
•Corona protection
Corona protection are comprised of conductive tape, which is
moulded during finale pressing cycle and becomes an integral part of
the coil side, integrally moulded corona tape systems limits of surface
resistivity are between 0.2 and 20 kΩ / square. On coils 11 kV and
above normally applied by silicone carbide grading paint with voltage
dependent resistivity (VDR) from the slot end through the first bend.
Wall insulation Corona Protection Silicone Carbide Grading Paint
•Coil overhang
Coil overhang, normally are consist of multiple layer of ½ lapped fully cured
mica tape and finished with a resin rich sealing tape, which produces a
water tight and smooth protective layer. A special high molecular weight
epoxy resin is applied between all layer of mica tape and is used to bond
the basic insulation materials together and fill many small voids. The resin
is not cured during coil manufacturing and therefore keeps flexibility in the
coil overhang making the coil easier and quicker to install. The complete
winding requires final oven cure.
•Coil overhang
Coil Test , Test references:
•IEEE standard , BS, EN, ESI
Strand – strand test at 240 volts AC
All coils with more than 1 strand in parallel per turn are strand – strand
tested. This test the integrity of the strand insulation between adjacent
strands of the same turn. Even though the voltage potential is very
small between strands, shorted strands can cause localized heating
due to an increase in eddy currents in shorted strands. This heating
can progress to damage to the strand and turn insulation and can lead
to turn-turn failures.
Turn-turn testing
All coils with more than 1 turn are turn to turn tested. This test the
integrity of the insulation between adjacent turn in the coil. Coils are
tested with 0.2 µs rise time to the equivalent 1.79 x line voltage with a
minimum of 5 pulses.
The test equipment such as Surge comparison tester
High Potential Test of ground wall insulation
All coils are tested result are measured in leakage current (µA)
result of the testing are dependent on temperature and humidity , as
in most cases the coil is in an uncured state. Coil are tested for one
minute to the equivalent of `120% ( 2 x Line voltage + 1 kV ac ).
Coil are tested with DC with a multiplication factor of 1.73. steel
guards the length of the slot portion are fitted to the coils to simulate
the insertion of the coil into the stator slot.
Tangent Delta Testing
Tan Delta Testing measures the uniformity of manufacture by
measuring the dielectric loss angle at 0.2, 0.4, 0.6, 0.8, 1.0
increments of the Line voltage of the coil
Prototype testing
Some of tender requirements require extra prototype testing to be
carried out
Test can include:
•Impulse testing of turn insulation for simulation of lightning strike
•Destruction testing of turn insulation
•Impulse or Power frequency testing of Main insulation
•Destruction testing of main insulation
•Accelerated Voltage endurance testing with or without thermal
cycling
•Tan Delta testing at ambient temperature before and after a 900C
temperature rise
Test Based on IEEE and BS – EN
Turn to Turn Testing
Normally coils will be tested at 60% voltage with 0.2µs rise
time to the equivalent of 1.79 x Line voltage with a minimum of
5 pulses.
IEEE 522: 2004 BS EN 60034-15: 1996

Standard Test Voltage for
Standard Test Voltage:
coils 3 kV to 15 kV:
2.86 VL at 0.1µs min 5 pulses
Reduced with agreement:
(4VL + 5kV) x 0.65 at 0.2 µs,
- Resin Rich tested at 40% to 60% Voltage :
min 5 pulses
- VPI 60% to 80% voltage
Max : [(2xVL) + 1kV] x 1.7
Min Voltage : 350 V per turn
High Potential Test of Ground Wall Insulation
IEEE 95: 2002 ( > 5kV ) BS EN 60034-1: 2000

2 x VL + 1KV ac for 1 minute 2 x VL + 1 kV ac for 1 minute
Factor 1.2 or 1.7 maybe (or equivalent if rated 6kV or
applied greater)
Insulation Resistance
IEEE 43 - 2000
VOLTAGE RATING (VOLT) TEST VOLTAGE (VOLT)
1000 - 2500 500 – 1000
2501 - 5000 1000 – 2500
5001 – 12 000 2500 - 5000
 12 000 5000 – 10 000
TanDelta
(TanDelta
0.61VL  TanDelta
.2VL  TanDelta
0,20VL
.2VL)

TanDelta
2 1.2VL
Inter Strand Test
Normally strand coils to be tested at 240 Vac
IEEE BS EN 50209 : 1999

Test Voltage 110 V ac
Between conductor lamination insulation
Insulation Power Factor Tangent Delta Testing
IEEE 286: 2000 ( tip-up) BS

IEEE EN 50209 : 1999 BS EN 50209 : 1999
Test Voltage 110 V ac
Between conductor lamination insulation
Standard for coil 6kV or Standard for coils 5kV to 24kV
above (above 11 kV testing to be agreed)
Sample size to be adequate Sample Testing :
for statistical sampling <5MW, 10% of coils, min 10
analysis
5 to 50MW, min 30 coils+10% of coils.
>50 MW, 2&4 poles, All
>50MW, (6 poles or more) , min 30 coils +10% of coils
TanDelta
(TanDelta
0.61VL  TanDelta
.2VL  TanDelta
0,20VL
.2VL)

TanDelta
2 1.2VL
Insulation Power Factor Tangent Delta Testing
IEEE 286: 2000 ( tip-up) BS EN 50209 : 1999

Capacitance and Tan Delta change >50 MW, 2&4 poles, All
per increment of 0.2VL or greater >50MW, (6 poles or more) , min 30 coils +10%
step up to 1.2VL of coils
Per unit Tip-Up measured Testing Loss Tangent ( ≤ 11 kV )
Tan δ 2VL - Tan δ 0.2VL
IEEE Tan Delta 0.2 BS VLEN=50209
max: 1999
0.03
= Test Voltage 110 V ac
Tand δ 2VL TanBetween

D 0.6VLconductor-lamination
Tan Dinsulation
0.2VL
=
Cell capacitance within 10% of 2
calculated value 0.025 for 95% and 0.03 for 5%
Used for comparison testing of Maximum Tan Delta change per increment of
coils 0.2VL steps
= 0.005 for 95% and 0.006 for 5%
Prototype type test as per customer requirement

2
3
Impulse Testing of Turn Insulation (Simulation of Lightning

Strike)
This is a destructive test IEC requires two fully cured coils.
IEEE Std 522: 2004 BS EN 60034-15 : 1996
Impulse voltage between coil Impulse voltage between 2

terminals and earth (shield terminals of same coil.
simulating core). Impulse voltage of (4 x VL + 5kV) x
Impulse voltage of 5 x (VL [v2/v3 ] 0.65 with front time of 0.2 µs,
with front time of 0.2 µs, repeated 5 repeated 5 times
times. Insulation must not fail
Insulation must not fail
(TanDelta1.2VL  TanDelta 0.2VL)
2
3 TanDelta1.2VL
Impulse Testing of Turn Insulation (Simulation of Lightning

Strike)
IEEE Std 522: 2004 BS EN 60034-15 : 1996
Impulse voltage between coil Impulse voltage between 2

terminals and earth (shield terminals of same coil.
simulating core). Impulse voltage of (4 x VL +
Impulse voltage of 5 x (VL [√2/√3 ] 5kV) x 0.65 with front time of
with front time of 0.2 µs, repeated 5 0.2 µs, repeated 5 times
times. Insulation must not fail
Insulation must not fail
2
3
Impulse Testing of Main Insulation
IEEE Std 522 : 2004 BS EN 60034-15 : 1996
Impulse testing between coil Impulse voltage between coil
terminals and earth (shields terminals and earth (shields
simulating core). simulating core).
Impulse voltage of 5 x ( VL√2/√3 ] Impulse voltage of (4 x VL + 5kV) x
with front time of 1.2 µs. repeated 5 0.65 with front time of 1.2 µs,
times repeated 5 times
Insulation must not fail Insulation must not fail
IEEE BS EN 50209 : 1999
Tested with opened coil
Withstand 0.3 x VL ac applied to adjacent turn for 1
minute.
Immediately rise at 0.5 kV /s until breakdown
occurs
Voltage Endurance Testing for Formed
Coils
BS EN
IEEE 1043 : 1996
(N/A)
Coils to be hi-pot test at 110% of endurance voltage for 1
minute and Tan Delta tested before endurance test.
Test conducted at air.
All conductors connected to constant stable voltage with
protection, coil test sample to be 250 cm or half bar length .
Heater elements 75% length of heater plates. Heater plates to
be connected to earth and clamped to have < 0.2 mm gap with
the coil.
Test temperature range 1200C to 2400C. Temperature
measured every 15 minutes with a maximum rise of 20C
Supply voltage measured at every 0.1 hr. the timer is stopped if
no voltage.
Test completed when retest also fails.
Expected life if insulation statistically calculated.
This test a destructive test on five fully cured coils. This test can run for months.
Special Test
Endurance and Thermo cycling
Laboratory Diagnostic Tests of Stator Winding Insulation
Downtime at generating stations and industrial plants caused by failure of

stator insulation can be expensive. To minimize the risks of machine
insulation failure, insulation must withstand the stresses in high voltage
generators and motors.
If you purchase new stator windings or have spare stator windings,:
- How do you know that your stator windings meet the design
specification and perform as expected?
- How do you know the winding manufacturing quality that is relevant
to machine operation reliability and machine service lifetime?
1. Voltage Endurance Tests
voltage endurance tests on stator bars or coils in accordance with IEEE
Standard1043-1996 and IEEE Standard 1553-2002.
A voltage endurance test is an accelerated insulation-aging test. The test is
performed on stator bars or coils at much higher than normal operation stress
levels within a short period of time to simulate insulation aging during
machine operation. The test can predict the performance of the overall
insulation system and measure the manufacturing quality. A number of
diagnostic tests on stator insulation can be conducted before and after a
voltage endurance test.
Manufacturers of stator insulation could change its design, type of materials,
and the manufacturing process. The voltage endurance test can be done
at the prototype and production stage to ensure the quality consistency
during manufacturing. The test gives objective assessment of the quality of
stator insulation. If coils fail the test, a remedial action may be taken by the
manufacturer to improve the quality of coil manufacturing.
Voltage endurance tests can be applied to both new coils and spare coils to
check the quality and performance of the insulation system. Spare coils have
been stored for a long period of time and need to be tested to check their
performance
The number of specimens shall be at least four bars (two top and two bottom
bars) or two coils, but not more than 1% of the number of bars/coils in the
winding. Additional bars/coils may be needed in the case that a retest is
required, The specimens can be selected from the prototype stage and/or at
different stages of the production cycle.
Test parameters
The test voltage shall be selected from either of the two proposed schedules
defined in Table 1. It is important to note that the test times for each test will
depend on the test voltages selected from Schedules A or B.
Schedule A is associated with a longer minimum acceptable test life
(400 hours).
Schedule B is associated with a shorter minimum acceptable test life
(250 hours).
Test Voltage : 3.76 or 4.39 times line-to-ground rms voltage

Acceptance criteria
If all specimens survive test times greater than 400 hours (Schedule A) or 250
hours (Schedule B), the entire bar/coil population is deemed to have met the test
requirements.
Insulation failure during a voltage endurance test at 280 hours
• insulation failure.
Thermal Cycling Tests and Multi-Factor Tests
Large motors are exposed to frequent start/stop operations.
Pumped-storage generators and hydro-generators have frequent
load changes. All of those operations cause rapid heating and
cooling, i.e. thermal cycling effect on stator insulation.
Thermal cycling can cause
 loss of bond between copper and insulation;
 delamination and degradation of groundwall insulation;
 Insulation Failure
Thermal cycling tests on stator bars and coils according to IEEE Standard 1310
-1995 and IEC standards is to test the stator winding under multifactor
(electrical, mechanical, and thermal stresses) stress aging simultaneously to
simulate normal service conditions or conditions as required. To assess the
insulation performance under thermal cycling stress as the machine
experiences in service, The test insulation system is heated and cooled
at a prescribed rate for a number of cycles (e.g. 500 cycles). A number
of diagnostic tests on stator insulation can be conducted before and after a
voltage endurance test.
Avg Heating Rate 2.80 C/min
Avg Cooling Rate 3.10 C/min
Conductor Temps
Strength Section Insul Temps
Avr of Insul Temps
Ambient
Coil Installation and Testing
Visual examination coils and perform dimensional check, prior to installation
the coils should be pre warmed to ease installation and prevent the coils from
cracking
This can be achieved by warming them to approximately 400C via an
electrical welding machine or by placing them in a covered enclosed heated
with an electrical bar heater. Its recommended to stager throw the coils over 2
pitches when installing them, this should be performed with extreme care so
that the corners are not stressed.
Testing
Electrical tests are to be performed in the stated order after lifting each ¼ of
the coils and after the coils have completely fitted and wedges
Insulation Resistance Test ( for windings at 400C)
Apply test between each phase and the frame
The test should be conducted with a 2500 V Megaohmmeter tester or above.
The reading is taken after the test has been applied for 60 second
Minimum Resistance = 100 MΩ
(note : resistance halves with every 100C increased)
Polarization Index (PI) testing for coils > 3kV
A Pi test should be conducted at each stage prior to the high
potential testing. Applying constant 2500 V dc voltage between the
winding and frame for 10 minutes using a power driven megaohm
meter
High Potential Testing
Connect firmly a 50-60 Hz or dc High Potential source between the
winding under test and frame. Winding to be tested as a group are
connected together whilst any winding are to be connected to
earth via the frame
Coil Resistance Testing
Coil resistance reading to be compared ensuring balance between
phases
Curing
The coils can be fully cured by baking them at 1600C for 16 hours
after the installation has been completed

2-Stator Winding

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This material shall not be copied or published without the written approval by Siswanto

A. High Voltage Insulation Winding Systems and

Stator Core Separator

Stator Dovetail Tooth

Side Ripple Top Filler

Roebel transposition of the copper strands refers to the re-

Thickness mm 1.0 1.5 2.5 2.8

Wall insulation Corona Protection Silicone Carbide Grading Paint

IEEE 522: 2004 BS EN 60034-15: 1996

IEEE 95: 2002 ( > 5kV ) BS EN 60034-1: 2000

IEEE BS EN 50209 : 1999

IEEE 286: 2000 ( tip-up) BS

Insulation Power Factor Tangent Delta Testing

IEEE 286: 2000 ( tip-up) BS EN 50209 : 1999

Tand δ 2VL TanBetween

Prototype type test as per customer requirement

Impulse Testing of Turn Insulation (Simulation of Lightning

This is a destructive test IEC requires two fully cured coils.

IEEE Std 522: 2004 BS EN 60034-15 : 1996

Impulse voltage between coil Impulse voltage between 2

Impulse Testing of Turn Insulation (Simulation of Lightning

Impulse voltage between coil Impulse voltage between 2

Laboratory Diagnostic Tests of Stator Winding Insulation

Downtime at generating stations and industrial plants caused by failure of

If you purchase new stator windings or have spare stator windings,:

Test Voltage : 3.76 or 4.39 times line-to-ground rms voltage

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