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Testing and Reconditioning

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

• Measured by applying non-destructing vtg b/w winding and


frame.
• Measured directly by Megger or voltmeter
• Moisture absorption will reduce I.R.
• Therefore should be measured immediately after the machine is
stopped running.
• When machine temp. is lower than surrounding air moisture will
condense and gradually absorbed by insulation in turn reduces I.R.
By using voltmeter
Recommended value as per IS at 700C :
Megger 𝑅𝑎𝑡𝑒𝑑 𝑣𝑜𝑙𝑡𝑎𝑔𝑒 𝑖𝑛 𝑣𝑜𝑙𝑡𝑠
I.R. = 𝑀Ω
0.01 ∗𝑘𝑉𝐴 𝑟𝑎𝑡𝑖𝑛𝑔+1000

Minimum value is 0.5 M Ω


Dielectric absorption test:
• Recommended when no previous record of I.R. is available.
• Dielectric absorption is accumulation of electric charge within an
insulating material when P.D. is applied across it.
• Using megger I.R. readings are taken at every 30 min and graph is
plotted for I.R. verses time.

𝐼.𝑅 𝑎𝑡 60𝑡ℎ 𝑠𝑒𝑐


• 𝐷𝑖𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝐴𝑏𝑠𝑜𝑟𝑝𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑖𝑜, 𝐷𝐴𝑅 =
𝐼.𝑅 𝑎𝑡 30𝑡ℎ 𝑠𝑒𝑐
• Should not be less than 1.25
Polarisation Index test
• Gives quantitative information about insulation with respect to
moisture, dirt & other contamination.
𝐼.𝑅.𝑎𝑡 10𝑡ℎ 𝑚𝑖𝑛
• 𝑃. 𝐼. =
𝐼.𝑅.𝑎𝑡 1𝑠𝑡 𝑚𝑖𝑛
• Should be > 1.5 for class A &
> 2.0 for class B
Two voltage test
• Dielectric absorption tets at
two different voltages.

• High test voltage is about 4


times the low test voltage.

• 25 % difference in I.R. with


application of two different test
voltages indicate presence of
moisture.
Reconditioning of insulating materials
• Removal of loose dust
• Compressed air at 2.1-2.8 kg/cm2 from portable vacuum cleaner.
• Encrusted Dust
• Blocks mainly ventilating ducts.
• Removed by hard wood or fibre scraper.
• Oily Viscous Film:
• Removed by cheese cloth or petroleum solvent
• Excessive use of solvent may damage the insulation
• Cleaning with water:
• Water + detergent
• Recommended for class H insulation
Drying insulation
• External heat
• Baking in oven
• Boiler (Steam of boiler to heat top of m/c. Temp. should not exceed 90 0C.)
• By electric heaters & lamps
• Internal heat (For windings with resistance greater than
0.05Ω )
• DC machine (Armature shorted and field applied. Allowed to run half the
rated speed to avoid damage to damp or wet insulation. Then at rated
speed)

• Induction motor (Blocked rotor test with 25% of rated voltage)


Revarnishing
• To fill air packets, voids, air gaps to achieve perfect insulation

• 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.

Chamber heated upto 1000C by circulating steam or oil


for nearly 4 hrs. At same time hot air is pumped out by
vacuum exhauster. Moisture present will be evaporated.

Insulating varnish from varnish tank is allowed to flow in


vacuum chamber till windings are completely immersed.

Valve of varnish tank closed. Pressure from compressor


at 1.4 to 2.1 kg/cm2 is applied above varnish surface.
Forces varnish in all pores and coil interiors. Pressure
maintained for hour or half.

Valve of varnish tank opened. Varnish allowed to flow


back to tank under air pressure to drain out excess
varnish.

Valve is closed & armature is baked in chamber at 100 0C


to 1100C nearly 8 hrs until it becomes bone dry.
Insulating Oil
Properties as recommended by IS 335-1963
• Viscosity (Indicates fluidity. Low for better cooling effect)
• Insulation & dielectric strength (Dielectric Strength greatly reduces by presence of moisture,
dust, small fibres. Ideally 30kV with 2.5mm gap)
• Flash Point (Temp above which oil surface ignites spontaneously. Should not be less than 1600C)
• Fire Point (Temp at which oil ignites & starts to burn. Should be about 2000C)
• Purity (Should be free from sulphur & its compounds to avoid corrosion & accelerates sludge formation)
• Sludging (Slow formation of semi-solid hydro-carbons maybe acidic. Due to heat & oxidation blocks
passage of cooling oil. If bright copper surface exposed to oxygen sludging accelerates. Remedy:
1. Use oil free from sulphur & its components. 2. Avoid oxygen contact by providing conservator tanks)
• Acidity (Products of oxidation: CO2, volatile water soluble organic acids & water. Corrodes iron &
metallic parts. Can be reduced by using conservator tanks & breather. Limiting value of acidity after
oxidation 0.4 KOH/g)
• In addition following properties are also desirable,

• Water content : Should not be more than 5 ppm


• Acidity neutralisation value: 0.03 mg KOH/g

• Loss tangent at working temp. : 0.005

• Density at 200C- 0.89 g/cm3


Causes of deterioration of insulating oil
• Due to presence of following impurities
• Water
• Dissolved particles
• Carbon deposits
• Dirt & dust
• Sulpher
• Gases
• Acids
• Alcohols
• Acetones & aldehydes
• Sludge (Oxidation by product whose formation accelerated by temp & air contact)
Testing of transformer Oil as per IS 1866-
2000
• To check stability of transformer oil for its use.
Following tests are conducted,
• Flash Point Test
• Crackle Test

• Dielectric Strength of Transformer oil


Flash Point Test
• Continuously heated till a point is reached at which vapour formed
on the surface of transformer oil fires spontaneously.
• Temp. of oil at this point should not be less than 1300C to 1400C
Crackle Test
• To determine presence of water or moisture in oil
• Oil under test is taken in test tube & heated on a gas burner. If
water is present in the oil crackling sound is heard.
• Another method: Sample oil is taken in 250 ml glass beaker. Iron
rod of 12.5 to 15 mm size is heated to red hot & then plunged into
oil under test. If crackling sound heard indicates presence of water.
Dielectric strength of transformer oil
Construction & dimensions:
• Test cell - 100×60 mm cross section. Approx. 85 mm height
• Brass spheres – 12.7 to 13 mm diameter (Fitted horizontally)
• Gap b/w spheres – 2.5 +0.02 mm (Can be adjusted by calibrated gauge)
• Variac i/p supply – 230V (Given to step up transformer. Voltage from HV
winding is applied to gap b/w spheres )
• Voltmeter at LV side calibrated to read HV voltage directly
• Circuit breaker (To trip supply at break down voltage)
Oil taken from transformer or Ensure autotransformer pointer at
drum in clean bottles zero.
Test cell washed & filled with oil Switch on supply
upto 1cm above spheres
Voltage increased gradually until
Cold oil is used. (D.S. increases with breakdown
temp)
Test cell kept stand still so that If cotton impurities present they will
bubbles will disappear or removed align in strong electrostatic field &
with glass rod causes early breakdown but C.B.
won’t trip. Ignore this voltage
Oil shouldn’t be touched to avoid
absorbing moisture from fingers Record final breakdown voltage at
which C.B. also trips. Ideal value 30
Test cell then covered with glass kv for 2.5 mm gap & 45 kv for 4 mm
cap gap.
Minimum break down values from different kV rating transformers with 2.5 mm gap

Transformer H.V. – Rating in kV


Oil Sample Upto 11 11-30 66-220 220 400
kV
Fresh oil from 25 30 40 45
drum

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

• Planned & well organised schedule of maintenance carried out at predetermined


intervals in order to avoid possibility of major faults. Thus it prevents damages &
breakdown. Carried out weekly, fortnightly, monthly, quarterly, yearly, two yearly
or five yearly.
• Maintenance schedule charts prepared accordingly.
• Inspection of loose parts, oiling, greasing, cleaning of coils, replacement of
weared out parts or repairs.
• Breakdown

• Carried out immediately when breakdown or fault takes place.


• Faults may be due to short circuit, overheating, earth fault, failure of
bearings etc.
• Steps are taken to repair the fault, rewinding is carried out if necessary.
Causes of failure of Electrical machines:
• Internal causes • External causes
• Overloading • One of the phase goes out(Single
• Short circuit phasing)
• Phase to ground fault • Short circuit in supply system
• Non-uniform air gap • Change in frequency
• Single phasing (One of the three • Overvoltage or under voltage
phase winding open circuited)
• Negative sequence currents due
• Magnetic locking of teeth to unbalanced supply system
(Cogging)
• Inter turn fault
• Worn out bearings
• Bad lubrication
Procedure of developing preventive
maintenance schedule
• Should not be too frequent
• Should not be too less frequent

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

Damage of insulation -Prolonged overload -Check voltage


-Temperature rise -Reduce load
-Over-voltage

Open contacts -Dry soldering -Re-soldering of joints


-Melting of contacts -Clean the contacts
-Due to opening of soldered
joints
Burning & darkening of -Due to dirt & dust accumulation -Clean the commutator
commutator -Improper brush tension -Adjust the brush tension
-Gap between commutator &
brushes

Wrong pole polarity Wrong connection of field coils -Change field coil connections
Magnetic faults
Fault Reasons Remedial Measures

Abnormal heating of core -Increased core losses -Tightening of the core


(-Failure of insulation b/w laminations stampings
-Increased flux density i.e. increase in supply -Adjust supply to rated
voltage or frequency) voltage & frequency
-Non-uniform distribution of flux density

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.

Daily -Visual earth connection & leads


-Temperature
-Check noise level & thus bearings
Weekly -Check belt tension
-Examine starters, contacts etc.
-Check bearings
Monthly -Check vibration due to imbalance of the motor or improper
coupling
-Inspect & clean circuit breakers
-Oiling & lubrication for damp & dusty locations
-Clean brush holders
Half yearly -Measurement of insulation resistance
-Checking of the air gap

Annual Check noise of bearings


2 or 5 yearly Over haul depending on duty cycle
Maintenance schedule of Synchronous machines
Insp. Items to be Inspection notes Action required if unsatisfactory
Frequency inspected condition
Monthly -Ball & roller -Check for noise -Check colour change of oil. If it
bearings -Check for oil or grease leakage becomes dark replace immediately
-Check for change in oil colour
-Brushes -Check length of brushes -Replace if worn out
-Commutator -Check commutator roughness -Wipe with a brush or lintless cloth
-Check for dust & wear
-Collector -Check if brushes are bouncing -Wipe with brush or a cloth
-Check collector roughness -Check collector continuity
-Air filters -Check if clogged -Replace
6 months -Insulation -Measure 1 min & 10 min insulation -wipe deposits from brush,
resistance (Polarisation index test) commutator, field coils etc
-Shaft -Check corners & key way for signs of -Do the needful
cracking
-Vibrations -Check balance & alignment of shaft -Do the needful
Yearly -Bearings -Drain out housing. Inspect bearing -If slug is found at the bottom clean it
surface & bottom half of it
Maintenance schedule of Batteries
Inspection freq Insp. Notes
Daily -Inspect room for general cleanliness
-Keep record of topping
-Check voltage of pilot cells
-Sp. Gravity & temp. of the electrolyte
-Record & check ambient temp.
Weekly -Inspection of batteries for dirt & dust deposition
-Check cells for cracks & electrolytic leakage
-Record & check sp. Gravity, temp, voltage
-Give quick fresh charging after heavy discharge
Fortnightly -Topping of all cells with distilled water
Quarterly -Check sp. Gravity, temp., voltage
-Check electrolyte level
-Check bolts & nuts
-test battery load & small continuous load
Yearly -Check condition of individual cell
-Resistance
-Inspection of battery rack
-Level of sediment collected at bottom
-Paint racks & walls of the room if need with acid resistance paint

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