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    Electrical Insulation for Rotating Machines

    Design, Evaluation, Aging, Testing, and Repair

    AvGreg C. Stone,Ian Culbert

    Inbunden, Engelska, 2014

    Del 83 i serien IEEE Press Series on Power and Energy Systems

    1 283 kr

    Tillfälligt slut

    Beskrivning

    A fully expanded new edition documenting the significant improvements that have been made to the tests and monitors of electrical insulation systemsElectrical Insulation for Rotating Machines: Design, Evaluation, Aging, Testing, and Repair, Second Edition covers all aspects in the design, deterioration, testing, and repair of the electrical insulation used in motors and generators of all ratings greater than fractional horsepower size. It discusses both rotor and stator windings; gives a historical overview of machine insulation design; and describes the materials and manufacturing methods of the rotor and stator winding insulation systems in current use (while covering systems made over fifty years ago). It covers how to select the insulation systems for use in new machines, and explains over thirty different rotor and stator winding failure processes, including the methods to repair, or least slow down, each process. Finally, it reviews the theoretical basis, practical application, and interpretation of forty different tests and monitors that are used to assess winding insulation condition, thereby helping machine users avoid unnecessary machine failures and reduce maintenance costs.Electrical Insulation for Rotating Machines: Documents the large array of machine electrical failure mechanisms, repair methods, and test techniques that are currently availableEducates owners of machines as well as repair shops on the different failure processes and shows them how to fix or otherwise ameliorate themOffers chapters on testing, monitoring, and maintenance strategies that assist in educating machine users and repair shops on the tests needed for specific situations and how to minimize motor and generator maintenance costsCaptures the state of both the present and past “art” in rotating machine insulation system design and manufacture, which helps designers learn from the knowledge acquired by previous generationsAn ideal read for researchers, developers, and manufacturers of electrical insulating materials for machines, Electrical Insulation for Rotating Machines will also benefit designers of motors and generators who must select and apply electrical insulation in machines.

    Produktinformation

    • Utgivningsdatum:2014-08-22
    • Mått:155 x 236 x 38 mm
    • Vikt:1 044 g
    • Format:Inbunden
    • Språk:Engelska
    • Serie:IEEE Press Series on Power and Energy Systems
    • Antal sidor:672
    • Upplaga:2
    • Förlag:John Wiley & Sons Inc
    • ISBN:9781118057063

    Utforska kategorier

    • Elektronik och kommunikationer inom Naturvetenskap och teknik

    Mer om författaren

    GREG C. STONE, PhD, is an electrical engineer working at Iris Power L.P. in Toronto, Canada (a company he helped to form). Prior to that, he worked for the Research Division of Ontario Hydro, which at that time was the largest electric power utility in North America.IAN CULBERT currently works as a rotating machine engineer at Iris Power L.P. in Toronto, Canada. Prior to that, he was a specialist at Ontario Hydro (now Ontario Power Generation Inc.) where he provided technical support to power station project engineering, operations and maintenance staff on the design, specification, maintenance, and repair of all types of motors and standby generators. Prior to that, he was a motor designer.EDWARD A. BOULTER, Lt. Commander (Ret.), USN Reserves, is now a consulting engineer. Previously he spent nearly forty years working as project/senior engineer and technical team leader designing machine insulation systems at General Electric.HUSSEIN DHIRANI was a senior generator design engineer at Ontario Power Generation.

    Recensioner i media

    “This book is incredibly useful for engineers diagnosing problems in rotating machines. . . Engineers, researchers, developers, and manufacturers of insulation systems for rotating electrical machines will benefit greatly from this book.”  (IEEE Electrical Insulation Magazine, 1 January 2015)

    Innehållsförteckning

    • Preface xixChapter 1 Rotating Machine Insulation Systems 11.1 Types of Rotating Machines 11.1.1 AC Motors 21.1.2 Synchronous Generators 41.1.3 Induction Generators 61.1.4 Permanent Magnet (PM) Synchronous Motors and Generators 71.1.5 Classification by Cooling 71.2 Winding Components 91.2.1 Stator Winding 91.2.2 Insulated Rotor Windings 101.2.3 Squirrel Cage Induction Motor Rotor Windings 111.3 Types of Stator Winding Construction 111.3.1 Random-Wound Stators 121.3.2 Form-Wound Stators—Coil Type 121.3.3 Form-Wound Stators—Roebel Bar Type 131.4 Form-Wound Stator Winding Insulation System Features 141.4.1 Strand Insulation 141.4.2 Turn Insulation 171.4.3 Groundwall Insulation 191.4.4 Groundwall Partial Discharge Suppression 211.4.5 Groundwall Stress Relief Coatings for Conventional Stators 241.4.6 Surface Stress Relief Coatings for Inverter-Fed Stators 271.4.7 Conductor Shields 291.4.8 Mechanical Support in the Slot 301.4.9 Mechanical Support in the End winding 321.4.10 Transposition Insulation 341.5 Random-Wound Stator Winding Insulation System Features 361.5.1 Partial Discharge Suppression in Inverter-Fed Random Windings 371.6 Rotor Winding Insulation System Components 381.6.1 Salient Pole Rotor 401.6.2 Round Rotors 411.6.3 Induction Machine Wound Rotors 43References 45Chapter 2 Evaluating Insulation Materials and Systems 472.1 Aging Stresses 492.1.1 Thermal Stress 492.1.2 Electrical Stress 502.1.3 Ambient Stress (Factors) 522.1.4 Mechanical Stress 532.1.5 Radiation Stress 542.1.6 Multiple Stresses 542.2 Principles of Accelerated Aging Tests 542.2.1 Candidate and Reference Materials/Systems 552.2.2 Statistical Variation 552.2.3 Failure Indicators 612.3 Thermal Endurance Tests 622.3.1 Basic Principles 622.3.2 Thermal Identification and Classification 632.3.3 Insulating Material Thermal Aging Test Standards 642.3.4 Insulation System Thermal Aging Test Standards 642.3.5 Future Trends 672.4 Electrical Endurance Tests 672.4.1 Proprietary Tests for Form-Wound Coils 682.4.2 Standardized AC Voltage Endurance Test Methods for Form-Wound Coils/Bars 692.4.3 Voltage Endurance Tests for Inverter-Fed Windings 702.5 Thermal Cycling Tests 712.5.1 IEEE Thermal Cycling Test 722.5.2 IEC Thermal Cycling Test 732.6 Nuclear Environmental Qualification Tests 742.6.1 Environmental Qualification (EQ) by Testing 752.6.2 Environmental Qualification by Analysis 762.6.3 Environmental Qualification by a Combination of Testing and Analysis 772.7 Multifactor Stress Testing 772.8 Material Property Tests 78References 80Chapter 3 Historical Development of Insulation Materials And Systems 833.1 Natural Materials for Form-Wound Stator Coils 843.2 Early Synthetics for Form-Wound Stator Coils 863.3 Plastic Films and Non-Wovens 893.4 Liquid Synthetic Resins 903.4.1 Polyesters 903.4.2 Epoxides (Epoxy Resins) 923.5 Mica 953.5.1 Mica Splittings 953.5.2 Mica Paper 963.5.3 Mica Backing Materials 983.6 Glass Fibers 993.7 Laminates 1003.8 Evolution of Wire and Strand Insulations 1013.9 Manufacture of Random-Wound Stator Coils 1023.10 Manufacture of Form-Wound Coils and Bars 1033.10.1 Early Systems 1033.10.2 Asphaltic Mica Systems 1033.10.3 Individual Coil and Bar Thermoset Systems 1043.10.4 Global VPI Systems 1053.11 Wire Transposition Insulation 1063.12 Methods of Taping Stator Groundwall Insulation 1073.13 Insulating Liners, Separators, and Sleeving 1093.13.1 Random-Wound Stators 1093.13.2 Rotors 110References 110Chapter 4 Stator Winding Insulation Systems in Current Use 1114.1 Consolidation of Major Manufacturers 1144.2 Description of Major Trademarked Form-Wound Stator Insulation Systems 115References 129Chapter 5 Rotor Winding Insulation Systems 1335.1 Rotor Slot and Turn Insulation 1345.2 Collector Insulation 1365.3 End Winding Insulation and Blocking 1365.4 Retaining Ring Insulation 1375.5 Direct-Cooled Rotor Insulation 1385.6 Wound Rotors 1395.7 Superconducting Sychronous Rotors 140References 141Chapter 6 Rotor and Stator Laminated Cores 1436.1 Magnetic Materials 1436.1.1 Magnetic Fields 1436.1.2 Ferromagnetism 1436.1.3 Magnetization Saturation Curve 1446.1.4 Ferromagnetic Materials 1446.1.5 Permeability 1456.1.6 Hysteresis Loss 1456.1.7 Eddy Current Loss 1466.1.8 Other Factors Affecting Core Loss 1466.1.9 Effect of Direction of the Grain 1486.1.10 Effect of Temperature 1486.1.11 Effect of Heat Treatment 1486.1.12 Effect of Impurities and Alloying Elements 1486.1.13 Silicon/Aluminum Steels 1496.2 Mill-Applied Insulation 1496.3 Lamination Punching and Laser Cutting 1506.4 Annealing and Burr Removal 1516.5 Enameling or Film Coatings 1516.6 Stator and Rotor Core Construction 1526.6.1 Stator Core Construction: General 1526.6.2 Hydrogenerator and Large Motor Stator Core Assembly and Support 1536.6.3 Turbogenerator Stator Core Assembly and Support 1546.6.4 Smaller Motor and Generator Stator Cores 1556.6.5 Rotor Core Construction 155References 157Chapter 7 General Principles of Winding Failure, Repair and Rewinding 1597.1 Failure Processes 1597.1.1 Relative Failure Rates of Components 1617.1.2 Factors Affecting Failure Mechanism Predominance 1627.2 Factors Affecting Repair Decisions 1647.3 Rapid Repair of Localized Stator Winding Damage 1657.4 Cutting out Stator Coils After Failure 1667.5 Bar/Coil Replacement and Half Coil Splice 1677.6 Rewinding 168References 169Chapter 8 Stator Failure Mechanisms and Repair 1718.1 Thermal Deterioration 1718.1.1 General Process 1718.1.2 Root Causes 1748.1.3 Symptoms 1758.1.4 Remedies 1768.2 Thermal Cycling 1768.2.1 General Process 1778.2.2 Root Causes 1808.2.3 Symptoms 1808.2.4 Remedies 1818.3 Inadequate Resin Impregnation or Dipping 1818.3.1 General Process 1828.3.2 Root Causes 1838.3.3 Symptoms 1848.3.4 Remedies 1848.4 Loose Coils in the Slot 1858.4.1 General Process 1858.4.2 Root Causes 1868.4.3 Symptoms 1898.4.4 Remedies 1908.5 Semiconductive Coating Failure 1908.5.1 General Process 1908.5.2 Root Causes 1918.5.3 Symptoms 1928.5.4 Remedies 1938.6 Semiconductive/Grading Coating Overlap Failure 1948.6.1 General Process 1948.6.2 Root Causes 1958.6.3 Symptoms 1968.6.4 Remedies 1968.7 High Intensity Slot Discharge 1978.7.1 General Process 1988.7.2 Root Causes 1988.7.3 Symptoms 1998.7.4 Repairs 1998.8 Vibration Sparking (Spark Erosion) 1998.8.1 General Process 1998.8.2 Root Cause 2018.8.3 Symptoms 2018.8.4 Repair 2028.9 Transient Voltage Surges 2028.9.1 General Process 2038.9.2 Root Causes 2048.9.3 Symptoms 2048.9.4 Remedies 2068.10 Repetitive Voltage Surges Due to Drives 2078.10.1 General Process 2078.10.2 Root Cause 2098.10.3 Symptoms 2098.10.4 Remedies 2108.11 Contamination (Electrical Tracking) 2118.11.1 General Process 2118.11.2 Root Causes 2148.11.3 Symptoms 2148.11.4 Remedies 2148.12 Abrasive Particles 2168.12.1 General Process 2168.12.2 Root Causes 2168.12.3 Symptoms and Remedies 2168.13 Chemical Attack 2178.13.1 General Process 2178.13.2 Root Causes 2188.13.3 Symptoms 2188.13.4 Remedies 2198.14 Inadequate End Winding Spacing 2198.14.1 General Process 2208.14.2 Root Causes 2228.14.3 Symptoms 2228.14.4 Remedies 2228.15 End Winding Vibration 2248.15.1 General Process 2248.15.2 Root Causes 2258.15.3 Symptoms 2268.15.4 Remedies 2278.16 Stator Coolant Water Leaks 2288.16.1 General Process 2288.16.2 Root Causes 2298.16.3 Symptoms 2308.16.4 Remedies 2308.17 Poor Electrical Connections 2318.17.1 General Process 2318.17.2 Root Causes 2328.17.3 Symptoms 2328.17.4 Remedies 233References 233Chapter 9 Round Rotor Winding Failure Mechanisms and Repair 2359.1 Thermal Deterioration 2359.1.1 General Process 2369.1.2 Root Cause 2369.1.3 Symptoms 2379.2 Thermal Cycling 2379.2.1 General Process 2389.2.2 Root Cause 2389.2.3 Symptoms 2409.3 Abrasion Due to Imbalance or Turning Gear Operation (Copper Dusting) 2419.3.1 General Process 2429.3.2 Root Causes 2439.3.3 Symptoms 2449.4 Pollution (Tracking) 2449.4.1 General Process 2449.4.2 Root Causes 2459.4.3 Common Symptoms 2459.5 Repetitive Voltage Surges 2459.5.1 General Process 2469.5.2 Root Causes 2469.5.3 Common Symptoms 2479.6 Centrifugal Force 2479.6.1 General Process 2479.6.2 Root Causes 2479.6.3 Common Symptoms 2489.7 Operating Without Field Current 2499.7.1 Loss of Field During Operation 2499.7.2 Inadvertent Closure of Generator Breaker 2499.7.3 Root Causes 2509.7.4 Common Symptoms 2509.8 Remedies 250References 252Chapter 10 Salient Pole Rotor Winding Failure Mechanisms And Repair 25310.1 Thermal Deterioration 25310.1.1 General Process 25310.1.2 Root Causes 25410.1.3 Common Symptoms 25410.2 Thermal Cycling 25510.2.1 General Process 25510.2.2 Root Causes 25510.2.3 Common Symptoms 25610.3 Pollution (Tracking and Moisture Absorption) 25610.3.1 General Process 25710.3.2 Root Causes 25710.3.3 Common Symptoms 25810.4 Abrasive Particles 25810.4.1 General Process 25810.4.2 Root Causes 25810.4.3 Common Symptom 25910.5 Centrifugal Force 25910.5.1 General Process 25910.5.2 Root Causes 25910.5.3 Common Symptoms 25910.6 Repetitive Voltage Surges 26010.6.1 General Process 26010.6.2 Root Causes 26010.6.3 Common Symptoms 26110.7 Salient Pole Repair 261References 263Chapter 11 Wound Rotor Winding Failure Mechanisms and Repair 26511.1 Voltage Surges 26611.1.1 General Process 26611.1.2 Root Causes 26711.1.3 Common Symptoms 26711.2 Unbalanced Stator Voltages 26711.2.1 General Process 26711.2.2 Root Causes 26811.2.3 Common Symptoms 26811.3 High Resistance Connections-Bar Lap and Wave Windings 26811.3.1 General Process 26811.3.2 Root Causes 26811.3.3 Common Symptoms 26811.4 End Winding Banding Failures 26911.4.1 General Process 26911.4.2 Root Causes 26911.4.3 Common Symptoms 26911.5 Slip Ring Insulation Shorting and Grounding 27011.5.1 General Process 27011.5.2 Root Causes 27011.6 Wound Rotor Winding Repair 27111.6.1 Failed Windings 27111.6.2 Contaminated Windings and Slip Ring Insulation 27111.6.3 Failed Connections in Bar-Type Windings 27111.6.4 Damaged End Winding Banding 27111.6.5 Failed or Contaminated Slip Ring Insulation 272References 272Chapter 12 Squirrel Cage Induction Rotor Winding Failure Mechanisms and Repair 27312.1 Thermal 27312.1.1 General Process 27412.1.2 Root Causes 27412.1.3 Common Symptoms 27512.2 Cyclic Mechanical Stressing 27512.2.1 General Process 27612.2.2 Root Causes 27712.2.3 Common Symptoms 27812.3 Poor Design/Manufacture 27812.3.1 General Process and Root Causes 27912.3.2 Common Symptoms 28112.4 Repairs 283References 284Chapter 13 Core Lamination Insulation Failure and Repair 28513.1 Thermal Deterioration 28513.1.1 General Process 28613.1.2 Root Causes 28613.1.3 Common Symptoms 28913.2 Electrical Degradation 29013.2.1 General Process 29013.2.2 Root Causes 29113.2.3 Common Symptoms 29413.3 Mechanical Degradation 29513.3.1 General Process 29513.3.2 Root Causes 29613.3.3 Symptoms 30113.4 Failures Due to Manufacturing Defects 30313.4.1 General Process 30313.4.2 Root Causes 30413.4.3 Symptoms 30413.5 Core Repairs 30513.5.1 Loose Cores 30513.5.2 Core Insulation Shorting 30613.5.3 Core Damage Due to Winding Electrical Faults 30713.5.4 False Tooth 30813.5.5 Cracked Through-Bolt Insulation 30813.5.6 Split Core Repairs 308References 309Chapter 14 General Principles of Testing and Monitoring 31114.1 Purpose of Testing and Monitoring 31114.1.1 Assessing Winding Condition and Remaining Winding Life 31114.1.2 Prioritizing Maintenance 31214.1.3 Commissioning and Warranty Testing 31214.1.4 Determining Root Cause of Failure 31314.2 Off-Line Testing Versus On-Line Monitoring 31314.3 Role of Visual Inspections 31414.4 Expert Systems to Convert Data Into Information 315References 316Chapter 15 Off-line Rotor and Stator Winding Tests 31715.1 Insulation Resistance and Polarization Index 31715.1.1 Purpose and Theory 32015.1.2 Test Method 32215.1.3 Interpretation 324References 385Chapter 16 In-service Monitoring of Stator and Rotor Windings 38916.1 Thermal Monitoring 39016.1.1 Stator Winding Point Sensors 39016.1.2 Rotor Winding Sensors 39216.1.3 Data Acquisition and Interpretation 39316.1.4 Thermography 394References 435Chapter 17 Core Testing 43917.1 Knife 43917.1.1 Purpose and Theory 43917.1.2 Test Method 44017.1.3 Interpretation 440References 461Chapter 18 New Machine Winding and Rewind Specifications 46318.1 Objective of Stator and Rotor Winding Specifications 46418.2 Trade-Offs Between Detailed and General Specifications 46418.3 General Items for Specifications 465References 486Chapter 19 Acceptance and Site Testing of New Windings 48719.1 Stator Winding Insulation System Prequalification Tests 48719.1.1 Dissipation Factor Tip-Up 48819.1.2 Partial Discharge Test for Conventional Windings 48819.1.3 Partial Discharge Test for Inverter Fed Windings 48919.1.4 Impulse (Surge) 490References 506Chapter 20 Maintenance Strategies 50920.1 Maintenance and Inspection Options 50920.1.1 Breakdown or Corrective Maintenance 51020.1.2 Time-Based or Preventative Maintenance 510Reference 525Appendix A Insulation Material Tables 527Appendix B Insulation System Tables 553Index 629