QUALITY CHECKS ON RESIN MIXTURE IN RESIN POOR PROCESS:

The resin mixture is a combination of epoxy resin and hardener.

The containers of resin and hardener are stored in a cool, dry place. They are
closed until processing for protecting against humidity. The impregnating
resin mixture in the ratio of 100 parts of epoxy resin is mixed to 100 parts of
hardener in a resin tank of the impregnation unit. The epoxy resin and
hardener heated in an oven at 125°C and sample is taken from every drum to
test before release. The resin mixture is sensitive to moisture and therefore it
is stored under vacuum below 20°C but chilled not below 8°C. After
thorough mixing, the resin mixture is tested.

TEST ON RESIN MIXTURE:

Before beginning impregnation and after stand still period of
more than five days. The resin mixture is tested in the following manner.

1. The resin mixture is tested for viscosity at 60°c and limiting value of
viscosity is 50m poise above which the resin is rejected.

2. The resin is again tested for the increase in its viscosity at 60°c after 20
hours heating at 100°c; the maximum value at this point is 9m poise.

3. The resin is then heated for its saponification number whose specified
value is 331.-+3 mg/koh/gram.

4. After this test for the ester number which is the between saponification
number and total acid number. Its maximum limiting value is 10. In case it
exceeds 10 necessary addition resin or hardener is done. According to
saponification number the resin mixture is released after each test for use.

TESTING PERFORMANCE OF RESIN POOR SYSTEM:

BEFORE IMPREGNATION PROCESS:
The different test which are carried out laying the bars in the stator
slots. They are:

1) Completion bottom layer high voltage test.

2) Completion top layer high voltage test.
3) Winding resistance measurement.

1. BOTTOM LAYER TEST

After laying the bottom bars high voltage test is conducted with 1.5
UP for 2minute where Up= 2Un+1, UP- Final test voltage Un-Rated voltage
of generator.

2. TOP LAYER TEST:

After laying the top bars high voltage test is conductor with 1.1 Up for
1 minute, where Up=2Un-Final test voltage of generator.

3. INTER CONNECTION CHECKING:

After completion of connection, winding and baking high voltage is

conducted with 1.05 Up for 1minute, when one phase is under testing, the
other phases are earthen measurement of resistance of individual phases give
the checking of interconnection.

4. A.C HIGH VOLTAGE TEST:

After laying top and bottom bars high voltage test with A.C is carried
out by connecting all other to ground.

5. MECHANICAL RUN TEST:

Dynamic test carried out to find various losses, they are

1. Mechanical losses
2. Iron losses
 3. Copper losses

AFTER IMPREGNATION:

After impregnation of the stator core by VPI process the

following tests are conducted:

1. TAN δ TEST.
2. HIGH VOLTAGE Tests.

TAN δ TEST:

After impregnation and curing of the winding a dissipation factor Vs

voltage measurement as stipulated in the application national and
international standard specification is performed for each bar between all-
individual phase winding to ground.

Guiding values for the deception factor and its rice with the voltage
merely. Given in the KEMA specification the maximum value shell not
exceed 0.001 at 20% of rated voltage and rise shell not be greater than 0.006
per 20% of rated voltage up to 60% of rated voltage and 0.08 per 20% of
rated voltage up to a rated voltage.

Winding manufacture by the Vacuum Pressure Impregnation Process comply

with these limits.

The above test results are specified in the following graphs. First graph
shows that voltage Vs Tan curve, it shows different Tan values at different
percentage of rated voltage 20%, 40%, 60%, 80%, 100% of rated voltage
respectively.

The second graph is a electrical field Vs life of insulation material, it

shows that resin poor system of insulation has very long life compared to
resin rich system of insulation. At 10 KV the resin poor system insulation as
a lifetime of 540 years. Any good machine as life span of 25-30 years by
using this insulation we will get a very long life with standard machine.
HIGH VOLTAGE AC TEST:

A C High voltage test is conducted on VPI system after impregnation to

verify proper impregnation and dielectric strength of insulation. This test
was conducted at 105% of winding test voltage i.e. Up=2Un+1KV Where
Up-Winding test voltage Un-rated voltage of machine.

ADVANTAGES OF RESIN POOR SYSTEM OF INSULATION

(1) It has got better dielectric strength
(2) Heat transfer coefficient is much better
(3) Maintenance free
(4) It gives better capacitance resulting in losses due to which the
insulation life will be more
(5) The cost is less and it is the latest technology
(6) Reduction in time cycle and consumption MW is also less and it
gives high quality

DISADVANTAGE OF RESIN POOR SYSTEM:

(1) Dependability for basic insulation materials on foreign countries
(2) If any short circuit is noticed, the repairing process is difficult

ADVANTAGES OF RESIN RICH SYSTEM OF INSULATION:

1. Better quality and reliability is obtained.

2. In case of any fault (Phase to ground (or) phase to phase short)

Carrying the repair process is very easy.
 3. Addition of excess resin will be avoided because of using resin
Rich mica tape.

DISADVANTAGES OF RESIN RICH SYSTEM OF

INSULATION:

1 It is a very long procedure.

2 Due to fully manual oriented process, the cost is more.
3 It is possible to process stator bars only.

COMPARISN BETWEEN RESIN POOR AND RESIN RICH SYSTEM

RESIN POOR SYSTEM RESIN RICH SYSTEM
1. The insulation tape used in this 1.The insulating tape material used
system has 8% of resin. in this system has 40% resin.
2. These method follows thermo- 2.It as in resin poor.
settling process.
3. There is a need for addition of 3.Further addition of resin is not
resin outside. required from out side
4. Reduction in time cycle for this 4 It is very long process and time
process. consuming.
5. No tests are carried out while at 5.Tests are being carried out while at
processing stage. processing stage.
6. Processing of bars along with 6.Processing of stator bars only
stator processing of exciter coils possible in resin rich system.
along with exciter are possible in
resin poor.
 7. The cost of repairs is more. 7. Repairing work is easy.
8 The over all cost is less 8. The total cost in this process is
compared to resin rich system. more.

APPLICATIONS:
1) All critical machines
2) Equipment exposed to frequent surges
3) Harsh or moist environment
4) Motors that run at service factor
VPI PROCESS CONTROL:
Throughout the VPI process computer to endorse homogeneous resin fill
continuously monitors each stator.

1) Ensure uninterrupted power supply

2) Adhere to the process strictly.
3) Assessments of critical failure in the system that can occur during
process and it emergency preparations.

ASSEMBLY OF STATOR AND ROTOR:

 Stator and rotor after their manufactured and tested they are
brought for assembly. Rotor is inserted into the stator using a crane and the
following are checked
♦ Bearing shell Id measurements
♦ Bearing shell blue matching
♦ Top and bottom blue matching of bearings
♦ Journal diameter
♦ Bearing shell & bedding top & bottom
♦ Stator alignment trough centering
♦ Air gap

TESTING OF TURBO GENERATORS:

OBJECTIVE OF TERSTING:
Testing is the most important process to be conducted on a machine after
it is designed. The testing of machine is necessary to establish that the
machine performance complies with the customer specification. Tests
ensure that the piece of equipment concerned is suitable for and capable for
performing duty for which it is intended.
Testing is done under conditions simulating as
closely as possible to those which will apply when the set is finally installed
with a view to demonstrate to purchaser’s representative its satisfactory
operation test provides the experimental data like efficiency, losses,
characteristics, temperature, limits etc for the use of design office, both as
conformation of design forecast and also as basic information for the
production of future designs.
INTRODUCTION:
With ever increasing rating of the modern turbo generator and
reliability of service expected, testing manufacture’s works has become of
paramount importance. The machine performance is evaluated from the
results of the equivalent tests.
ADVANTAGE OF TESTING:
1. Provide data for optimization of design
2. Provide quality assurance
3. Meets the requirement of legal and contract requirement
4. Reduction in rework cost
5. Ensure process capability and develops checklist
6. Increase confidence level in manufacture
7. Establish control over raw materials.

PERFORMANCE TESTS:
The performance tests on the turbo generator are classified as:
1. Type tests
2. Routine tests
3. Heat run tests
In our project we are doing only with Routine Tests.

ROUTINE TESTS:
These tests are carried out on each generator to ascertain that it is
electrically and mechanical sound. These tests are carried out on different
machines & are classified as:

1. STATIC TEST:
 • Measurement of Insulation Resistance of stator & Rotor winding
before &after High Voltage test (M/c at test)
• High voltage test on stator & rotor winding (M/c at rest)
• Measurement of polarization index of stator windings.
2. RUNNING TEST:
• Measurement of Mechanical losses, short circuit characteristic
and losses
• Measurement of Mechanical losses, Open circuit characteristic
and losses
• Measurement of rotor impendence (rotor inside stator)

STATIC TESTS
Measurement of insulation resistance of stator & rotor winding before and
after High voltage test:
Equipment:
(a) Megger (1000/2500v)
(b) Ear thing Rod earthing wire/ c able
* IR of the stator and the rotor winding are measured separately before and
after HV test using Megger of 2500V for stator & 1000V stator windings.
The values are taken at 15 sec and at 60 sec.
* Absorption coefficient of insulation is found out as
Absorption coefficient= 1Rat60″
1 Rat15″

This value should be> or= 2

If IR values are quite high, the absorption coefficient is not considered

because of early saturation (often observed in low voltage winding like rotor
etc). With dry winding its value will be some where in the vicinity of 2 or
even more. With damp winding it winding it will decrease to one.
Absorption coefficient of 1.8 & 1.7 may be satisfactory, while a value below
1.5 indicates a damp machine.
* Minimum IR value
The minimum value of insulation resistance (Rm) at 60min is
recommended as:
Rm =( Kv+1) ohms.
Where KV is voltage in kilovolts to be applied for tests.

In practice a fairly high value is obtained.

The winding is discharged to earthy after each measurement
2. Measurement of polarization index of stator winding:
The polarization index of stator winding, all the three phases together,
is measured using 2500v megger after HV test. The IR values are noted at 1
min and 10min from starting of measurement.
The PI is evaluated as follows
Polarization index (P.I) = I.R. Value at 10min/I.R. value at 1 min
The minimum allowable PI value is 2.0
3. High Voltage test:
Equipment
*50 Hz A.C High voltage transformers and its induction regulator/input
autotransformer.
* Potential transformer (35 or100KV/100V)
* Voltmeter
*Binding wire
* Earthing Rod and Earthing wire/cable
When H.V test is done on one-phase winding, all other phase
windings, rotor winding, instrumentation cables and stator body are earthed.
The high voltage is applied to winding by increasing gradually to required
value and maintance for 1 minute & reduced gradually to minutes. The
transformer is switched off & winding discharged to earth by shorting the
terminal to earth using earthing rod connected to earth wire/cable.
The test is conducted on all the phases & rotor winding separately.
HV Test Levels:
Stator winding: (2Ut+1) KV =23 for 11 KV machine
Rotor winding: (10 Up) volts (with min of 1500v & max of 3500v),
Where, Ut= Rated of machine under test Up= Excitation voltage.
 RUNNING TEST:
1. Measure of mechanical losses, short circuit characteristic and losses:
* The machine is prepared for short circuit characteristic using current
transformer and shorting links
* The machine is run at rated speed and drive motor input voltage
and current are noted and machine is excited
* Gradually in steps, at 20%, 40%, 80%, 90%&100% In. (In: rated
current of machine)
* At each step the following parameters are noted
a) Stator current (Ia&Ib)
b) Rotor current (If) corresponding to stator voltage.
c) Drive motor voltage (vd) and current (Id) corresponding stator
voltage
* The excitations is reduced and cut off, the speed is reduced and the
machine is cooled at lower speed. The machine is stopped when it is
sufficiently cooled down (stator core temperatures to be less than 60° c)
• From the above data, characteristic curves are plotted as
follows:
a) %In v/s If
b) %In v/n machine losses in kw
2.Measurement of mechanical losses, open circuit characteristic and losses:
* The machine is run at rated speed and drive motor input voltage and
current are noted and machine is excited gradually in steps, at 20%
En (En: rated voltage of machine)
* At each steps the following parameters are noted
a) Stator voltages (Vab, Vbc & Vca)
 b) Rotor current (if) corresponding to stator voltage
c) Drive motor voltage (Vd) and current (Id) corresponding stator
voltage.
The excitation is reduced and cut off , the speed is reduced and the machine
is cooled at lower speed. The temperature are checked from machine is
stopped when it is sufficiently cooled down (stator core temperature to be
less than 60°c)
* From the above data, characteristic curves are plotted as follows:
a) % En V/S If
b) % En v/s machine in Kw.
3. Measurement of rotor impedance (Rotor inside stator)
* Equipment:
a) 50HZ (power frequency) a.c.source
b) Ac/Dc power analyzer
c) Current transformer (50A/5A or 100A)
d) Connecting leads
A variable 50Hz A.C. voltage of 1Φ is applied across the slip rings
/input leads and readings of voltage and current are noted down
from 50V to 200V in steps of 50V
This test is done at 1/3, 2/3 and at rated speed
Evaluation of Impendence:
Z= V/I ohms
Where Z = impendence in ohms
V=voltage
I = Current
 Impendence measurement:
1. At rated rpm (Rotor inside stator)
2. At standstill (Rotor inside stator)
3. At standstill (Rotor outside stator)
TAN δ TEST:

Equipment: Schering Bridge

This test is conducted to check the presence of impurities in the
insulation & tanδ value for each phase & also for combined phases is noted
down.
Tan δ value should be generally less than or equal to 2%.

TESTING RESULTS:

Vph (0.2Un ) Rated KV= 10.5KV , 3000RPM.

Uph Tan δ
2.1 0.815
4.2 0.832
6.3 0.869
8.4 0.903
10.5 0.938

Wph Tan δ
2.1 0.806
4.2 0.820
6.3 0.857
8.4 0.899
10.5 0.941
 Vph Tanδ
2.1 0.811
4.2 0.830
6.3 0.868
8.4 0.905

Uph Vph Wph Tan δ

2.1 1.18
4.2 1.209
6.3 1.230
8.4 1.254
10.5 1.268

Rating: 31.25, 250 MW, 11KV, 1640A, 0.8pf, 3000rpm.

SCC:
Ia Ib %In If Vd Id Dm
O/P
0 0 0 0.01 559.0 404.58 226.16
337.2 337.6 20.57 94.7 515.95 443.1 228.60
664.8 666.2 40.5 187.1 516.04 481.4 248.44

1005. 1006.1 61.34 281.51 516.52 533.6 275.6

8
1324. 1326.5 80.84 369.16 516.54 651.25 336.35
9
1495. 1496.9 91.2 415.2 516.18 690.3 356.32
2

OCC:
Vab Vbc Vca %En If Vd Id Dm
 O/P
35.3 35.3 35.3 35.32 0.01 512.4 419.85 215.16
2281.2 2282.5 2281.8 20.74 40.44 512.93 423.15 216.62
4447.4 4441.4 4448.2 40.44 77.05 512.4 442.45 226.71
2
6662.0 6665.0 6663.0 66.58 116.65 512.3 466.43 288.95
8845.0 8849.0 8846.0 80.4 160.3 512.19 501.08 256.64
10015. 10019. 10017. 91.06 186.56 512.25 517.25 264.93
0 0 0
Resistance Measurement:
Instrument: Micro ohm meter
Resistance at 25°c (mΩ) Resistance at 20°c (mΩ)
Rotor 264 258.92

R75 = (( 235+75)/(235+20)) x R20= (310/255) x (0.2587)=0.3147 Ω

Rotor current = 562 A
Efficiency = (output)/(output+losses)
Losses = 99.532 + 9.9532 + 39.39 + 385.15 + 286. 38 = 820.40
Efficiency= (25000/25000 + 820 .40 ) = 96.82%
CONCLUSION:

Considering the manifold advantages of VPI System of insulation the

leading manufacturers of World are going to adopt this system for generators
up to 400 MW with hydrogen gas cooling. It has better thermal, electrical,
mechanical and chemical properties and its life time is about 54o years.

In view of the above, in the coming decades the Indian grids will use more
of such generators. In the scenario of World market which demands
generators with less cost at the best possible time with better reliability VPI
system of insulation will provide most viable solution.
B I B I L O G R A P H Y:

1. Electrical Machines: R.K.Batta Charya

2. Electrical Design, Operation and BHEL

Maintenance Manuals: Hyderabad

3. Engineering Chemistry: Daniel Yesudian

4. Electrical insulating Materials: R.K.Rajput

5. Electrical Machines: M.G.Say