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of insulating materials
Government Polytechnic
Dhule
Factors affecting life of insulation
• Temperature
• Moisture
• Mechanical stress
• Thermal stress
• Electrical stress
• Deposition of dirt, dust, oil
• Impurities
Classification of insulating materials
Class Insulating Material Uses Max Operating Temp
Y/O Cotton, silk, paper, pressboard, Hygroscopic therefore 900C
vulcanised fibre, wood, PVC rarely used
A Same as class Y/O but impregnated Paper in slot insulation, 1050C
in dielectric oil or varnish Cotton covered wires,
slot wedges
E Leathroid paper for slot insulation, Slot ins, winding wires, 1200C
Polyvinyl acetal (PVA), enamel for epoxy resins for chokes,
wires, epoxy resins, cotton fabrics C.T. etc.
and paper laminates.
(Alkyol & phenolic type varnish)
B Glass fibre, asbestos, mica, Slot liners, phase 1300C
varnished glass, fibre textile etc. separators, insulating
with bonding substance like tapes, binding cords, etc
shellac, bituminous compounds,
epoxy resins etc
Class Insulating Material Uses Max Operating Temp
F glass Same as class B , Varnished Slot liners, separators, 1550C
glass, fibre textile builtup mica, etc tapes, cords, etc.
with bonding substance like epoxy Polysterimide enamel
& silicon alkyl resins with fibre glass braided
& varnished with
polyurethane wires for
coils.
H Same as class F with binding Slot liners, separators, 1800C
materials s.a silicon based glass insulation tapers,
fabric, flexible micanite with conductor insulation,
suitabke resins or polyamide films, binding sleeves etc.
glass fabric tape or cord with silicon
elamoster cover
C Mica, porcelain, ceramic, glass, Same as class H, also ins Above 1800C
quarts, asbestos, treated glass fibre materials in ovens
and asbestos with inorganic binders
s.a glass or cement and silicon
resins, slate, marble
Measurement of insulation resistance and
interpreting from it insulation condition
• Types
• Air dry varnish by brush
• Air dry varnish by spray
• Hot-dip method using baking varnish
-Wound arm, stator or rotor heated at 1000C for hour to remove moisture. Then
immersed in moisture for half an hour. Therfore air packets gets filled.
Kept on iron grill to remove excess varnish.
Inside baking oven at 100-1100C for 4-8 hr.
• Vacuum Impregnation by baking varnish
Construction and working of vacuum
impregnation plant
Consist of-
• Vacuum
Impregnating
chamber
• Varnish Tank
• Heater
• Compressor
Wound armature, stator or rotor kept in vacuum
chamber.
Oil from 20 25 35 40 45
transformer
tank
Method of purification and filtration of
insulating oil
To remove solid impurities, dissolved moisture. To dry transformer
oil and increase insulation resistance.
• Cetrifugal purifiers
• Stream line purifiers (Filter pack-type)
• Filters using activated earth media
Centrifugal Pumps Makes use of difference in specific
gravity of transformer oil and
impurities in form of water, dust or
carbon particles.
Streamlined Filter (Vacuum type)
• Also known as vacuum type purifier.
Impure oil enters oil inlet pipe where it is Purified oil withdrawn from central hole in
heated at 600 to 700C. Makes oil thin & paper pack through which holding bolt
easier to remove impurities. Also releases passes.
dissolved gases & moisture. (Immersion
type heaters with low surface temp)
Dust or dirt, sludge & water collected on
outer paper packs are removed by
Heated oil pumped into purifier chamber & admitting air into central hole of the pack &
passed through stacks of thin paper discs are drained out from drain valve.
(6 kg/cm2) which are tightly packed &
compressed by powerful springs. Purified oil enters vacuum tank where oil is
exposed to sudden reduction in pressure
Stack of filter paper can remove even which lowers its boiling point.
microscopic impurities.
Therefore, dissolved moisture, air or gas are
Impurities accumulate on outer surface of liberated leaving behind dry perfectly dry
filter pack. oil with high insulating strength.
Filters using activated earth media
• Moisture in oil removed by special dehydrating powders.
• ‘Meta Sil’ based on active alumina or other earth media.
• Powder mixed with oil by using external handle & is pumped through
meta-filter packs.
• Similar to streamline but made up of metal rings instead of paper discs.
• Metal plates have small indentations (Notch) on sides through which
allows oil to pass but blocks meta sil powder.
• Hence get deposited on outer surface of filter elements.
• Similar dirt, dust & carbon gets deposited on outer surface.
• Meta sil provides fine pores which only allows oil to pass through it.
Maintenance of Electrical Machines
• To reduce the fault occurrence.
• Hence increase the life & reduce down period of equipment's thus
increase in production.
• Ensure continuity of operation & prevent machine from breakdown.
Ensure satisfactory working & prevents faults in future.
Types of maintenance
• Routine
• Consist of maintenance programme which can be carried out daily.
• For machines: Cleaning of dust by blowers, soft cloth etc., recording of
load current, voltage, checking of earth connection, temperature,
vibrations, noise etc.
• Preventive
Procedure:
• Age of the machine
• Duty cycle
• Cost of the machine
• Overload working of the machine
Preventive maintenance
• Advantages:
Factors affecting preventive maintainence
schedule
• Access to reach machines
• Mode of operation of the plant
• Management decision
• Unforeseen causes
• Working not consistent
• Failure of the machine
• Replacement of the machine
Different types of faults
• Mechanical
• Electrical
• Magnetic
Mechanical faults
Fault Reason Remedial measures
Improper bearing operation Improper lubrication of bearing, bad quality of -Check coupling
lubricant, vibration set up by rotating masses -Load m/c properly
due to unbalance weight or improper coupling -Stop m/c if vibrations are
excessive
Out of roundness in Commutator segments might not have been Use tightening rings to give round
commutator pressed properly shape again
Bent shaft Due to eccentric coupling of load Proper nut fittings of coupling
Tight belt Alignment of coupling
Mishandling during transport & storage
Projection of separate Loosening of commutator bars
commutator bars
Sparking b/w commutator & Low brush pressure
brushes Improper brush spring tension
Bushings develop cracks Change in atmospheric conditions Cleaning of Dust & dirt
Electrostatic stress
Damaged gaskets Atmospheric conditions
Reaction of oil with gasket material
Tap changer not working Damaged contacts due to frequent arcing Clean the contacts & remove the
properly carbon
Electrical faults
Fault Reasons Remedial measures
Wrong pole polarity Wrong connection of field coils -Change field coil connections
Magnetic faults
Fault Reasons Remedial Measures
Loose poles -Vibrations of the machine (Abnormal speed, Tight fitting of poles
loose foundation) with yoke
Misalignment of poles Unequal spacing b/w the poles -Do necessary
alignment
-Nut-bolt fitting
Non-uniform air gap Damaged bearings
Wrapped & dented core Damaged insulation cause sharp rise in core -Necessary repairs
losses -revarnishing the core
-Replacement of
damaged stampings
Maintenance schedule of Distribution transformer
Freq of Inspection Inspection details Actions required if
inspection conditions
unsatisfactory
Hourly Load, Temperature, voltage Check against rated Start fan
Daily Dehydrating breather -Check air passages are clear If silica gel is pink change
-Check colour of active agent
Monthly Oil level in transformer -Top up with dry oil
-Examine for leaks
Quarterly Bushings -Check for crack & dirt deposits -Clean or replace
Half-yearly Non-conservator Check for moisture cover Improve ventilation, check
transformer oil
Yearly -Oil in transformer Examine relay & alarm contacts, their -Replace contacts & fuses
-Earth Resistance operation etc. if necessary
-Relays, alarms & their ckt Check relay accuracy -Change settings if
necessary
2 yearly Non-conservator Internal inspection of cores Filter oil
transformers
5 yearly Non-conservator Overall inspection, lifting of core & Wash by spraying a dry oil
transformer coils
Maintenance schedule of Power transformer
Freq of Inspection Inspection details Actions required if conditions
inspectio unsatisfactory
n
Hourly -Ambient temp -Check if values are within permissible -if abnormal heating: Shut down
-Winding temp limits transformer
-Oil temp -
-Load, voltage -Check against rated figures
Daily -Oil level in transformer, -Top up with dry oil examine for
bushings leaks
-Silica gel breather -Check air passages are free. Check colour -If turned pink replace
Quarterly -Bushings -for cracks & dust -Clean or replace
-Oil -Check dielectric strength & waste content -Filter or replace
-cooler fan bearings, motors -Lubricate bearings -Replace burnt contacts
& operating mechanism -Examine contacts
Half-yearly Oil cooler Test for pressure
Yearly or -Oil in transformer -Check for acidity & sludge -Filter or replace
earlier -Oil filled bushings -Test oil -Filter or replace
-Gasket joints -Tighten the bolts replace if leak
-Surge diverter, relays, -Examine cracks & dirt deposits. Examine -Clean or replace
alarms ckt etc. relay & alarm contacts, operations of relays -Clean contacts, replace fuse or
-Earth resistance & fuses contacts change settings if
Freq of inspection Inspection Inspection details Action required if
conditions
unsatisfactory
5 yearly 1000 kVA to 3000 Overall inspection Wash by spraying dry
kVA oil
10 yearly Above 3000 kVA
Maintenance schedule of Single phase & three phase I.M.